Operating instructions

H1281/...
Primezone
Control unit

GB 05 / 21 HK
Introduction

Dear customer,

thank you for having chosen a HASCO temperature controller. 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 before bringing the device into servi-
ce !

Connect Wiring the device should be done by your qualified electrician following the in-
structions given in this manual.

Warranty period is 1 year and includes all malfunctions clearly caused by material, pro-
duction 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.

Carefull packaging is essential for a safe shipment !

Small repairs up to the maximum amount mentionned in our commercial terms and conditi-
ons 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

Warning, imminent danger

General information

Wiring and installation advice

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 Operations manual H1281

Disclaimer

Compliance with the operating instructions is a prerequisite for the safe operation of the
controller unit and for achieving the specified product and performance characteristics.
HASCO Hasenclever GmbH + Co KG is not liable for personal injury, property damages or
financial losses that arise from non-compliance with the operating instructions. Warranty for
defects is excluded in such cases.

This controller unit has been designed and built safely by us and also left the plant in a safe
and proper working condition. To maintain this condition and to ensure safe operation, the
user must follow the instructions and warnings described in this manual and the safety in-
structions herein included.

Since the observance of safety is outside our sphere of influence, we cannot be held liable
for damages resulting from failure to comply with one or more of these rules. The list of safety
regulations can not be complete (mechanical and foreign regulations). Not mentioning or lis-
ting these rules does not mean that they have no validity.

Commissioning, maintenance and repair work may only be performed by persons which are
recognized as professionals within the meaning of current legislation (VDE-rules, safety law
for electrical equipment, accident prevention legislation of the employers liabilities insurance
association).

Warranty limitations

The content of this documentation has been carefully established and thouroughly verified.

HASCO Hasenclever GmbH + Co KG assumes no responsibility for any damage that may
arise from errors in the documentation. In particular, descriptions and technical specifica-
tions are not warranted characteristics in a legal sense.

HASCO Hasenclever GmbH + Co KG has the right to make changes to the product descri-
bed or documentation without prior notice, if they are made for reasons of reliability and qua-
lity improvements, or by technical progress.

We always appreciate any advice for possible errors or potential improvements, that help us
provide you with even better products and services in the future.

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 Table of content
Chapter Page

0 Introduction…………………………………………………………….. 2

1 Features.……………………………………………………………….. 5

2 Safety advice…………………………………………………………… 6
2.1 Environmental advice…………………………………………………. 7
2.2 Qualification of personnel…………………………………………….. 7

3 Specification…….……………………………………………………… 9

4 Installation and wiring…...…………………………………………….. 11

5 Operation.………………………………………………………………. 15
5.1 Main switch...…………………………………………………………… 15
5.2 Operating elements and keys..……………………………………….. 15
5.3 Touchscreen……….…………………………………………………… 16

6 HASCO Touchscreen Operation System...…………………………… 18

6.1 „Homescreen“…………………………………………………………… 18
6.2 Part „Hotrunner“ - view total situation…………………………………. 19
6.2.1 Zones - view in groups. ………………………………………….. 22
6.2.2 Zones - detail view...……………………………………………… 23
6.3 Part „Settings“………...………………………………………………… 33
6.3.1 Settings - User…………….………………………………………. 33
6.3.2 Settings - Language….…...……………………………………… 36
6.3.3 Settings - System……..………………………………………….. 37
6.3.4 Settings - Zones configuration….....……………………………. 45
6.4 Part „Mould diagnosis“………………….……………………………… 61
6.5 Part „Real time analysis“……………………………………………….. 65
6.6 Part „Mould memory“ ………...………………………………………… 67
6.7 Part „Alarms“………..….……………………………………………….. 71

7 Keyword index……...…………………………………………………… 73

8 CE-conformity certificate……………………………………………….. 76

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 Operations manual H1281

1 Features
Ready to use compact multizone temperature controller for all 230V hotrunner systems

- Compact unit for 6 up to 48 zones

- User friendly touchscreen operation with HASCO Touchscreen Operation

System

- Adaptive control algorithm with automatic self-tuning for every zone

- Safety load-shedding for process-high temperature

- Synchronized heating for all zones possible

- Boosting for „frozen“ nozzles possible

- Integrated heater current monitoring

- Intelligent, programmable soft start routine

- Programmable alarm settings for every zone and various self-monitoring

functions

- Standard with mould diagnosis function

- Mould memory and real-time data analysis

- Smartphone- or tablet operation with integrated WIFI

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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 electrical device driven with high voltage, please respect the current 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. Clean the surface of the touchscreen only with appropriate, soft cleaning material,
never use solvants or abrasive detergents or material.

9. Don‘t place the device on hot machine surfaces or near radiation sources of hot
parts.

10. Keep the power connection cable clear of hot parts or sharp edges.

11. 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.

12. Operation of the device and any other intervention must only carried out by
qualified staff members following chapter 2.2 .

13. For repair, the device should be send back to our factory. Attempted selfrepair
causes immediate termination of the warranty period !
If spare parts are required, only parts recommended by the supplier must be used.
The use of other parts may cause damage and/or hazard for operation personnel.

14. Please respect further recommandations and warnings described in this opera-
tions manual.

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 Operations manual H1281

2.1 Environmental advice

1. This device has been produced according to EU-directive 2002/95/EG(RoHS), this

applies also to all of its components.

2. The approved range of climatic conditions may not be left during current operation.

3. The published degree of protection of the device must be taken into account when
defining the operational and environmental conditions of use.

4. This device must not be used in areas exposed to explosion hazards.

5. Electronic scrap, electronical devices and their components are subject of specific
regulation concerning treatment of special refuse and may only be disposed by
certified bodies.

2.2 Qualif ication of personnel

For the use and operation of this device, the following requirements regarding
qualification and training of the personnel must be taken into account :

1. Operator
2. Tool setter / shift leader
3. Administrator
4. Maintenance and repair personnel
5. Manufacturer

Definition of the different qualification levels see next page.

.

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 To 1.) Operator
- Scope of activities :
Starting and stopping of current operation, reading of actual operational situation and
current alarms, limited altering of heating parameters
- Qualification :
Trained for the operation of the actual device and its risks and hazards by a qual ified
person, at least of the level „Tool setter / shift leader“

To 2.) Tool setter / shift leader

- Scope of activities :
As 1.), additionally altering of more heating parameters in the zones configuration,
loading and saving of mould data into or from the mould memory, performing of mould
diagnosis program
- Qualification :
Professional training or equivalent experience, trained for the operation of the actual
device and its riscs and hazards by a qualified person, at least of the level „Tool set-
ter / shift leader“
“

To 3.) Administrator
- Scope of activities :
As 2.), additionally configuration of system parameters such such as memory settings
or interface configuration, executing of back-ups or software updates in coordination
with the manufacturer of the device
- Qualification :
Professional training or equivalent experience, trained for the operation of the actual
device and its riscs and hazards by a qualified person, at least of the level „Adminis-
trator“

To 4.) Maintenance– and repair personnel

- Scope of activities :
As 3.), additionally assembly of cables and wiring harnesses, default finding and repla-
cement of components inside the device while using original parts
- Qualification :
Electrically skilled person is imperative, trained for the operation of the actual device
and its riscs and hazards by a qualified person, at least of the level „Administrator“

To 5.) Manufacturer
- Scope of activities :
All activities exceeding 4.), especially modifications, upgrading of functions and up-
dating of the devices software

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 Operations manual H1281

3 Specif ication

Mains voltage :
230/240V +/- 10%, 48...63 Hz

Nominal rating/nominal current :

Max. 16A per zone
Up to 8 zones : max. 11 kW / 3 x 16A total
12 to 32 zones : max. 22 kW / 3 x 32A total
40 and 48 zones : max. 22 kW / 3 x 32A total

Fuses :
16A FF, 6,3x32mm, heating-loads
5A mT, 5x20mm, controller

Standby / alarm-exit :
7-pin plug:
2 floating contacts (230VAC, max. 3A) for alarms.
One 24V DC input to activate the 2nd (standby-) temperature-value for all zones
simultaneously, wired in parallel with the internal “stand-by” switch.

Safety load-shedding :
Disconnection of all heating loads in case of process-high alarm +50°C, cannot be de-
activated

Heating load alarm :

0,0 ... 19,9A adjustable
Min. 0,4A factory default setting

Sensor inputs :
Thermocouple Fe-CuNi, type J, 0...400°C or 800°C adjustable
Internal zero point correction
Sensor is monitored for cable breakage, short-circuit and polarity errors.
Thermocouple Ni-CrNi, type K adjustable, internal wiring „K“ on request

Touchscreen
Capacitive 10“ touchscreen with glass surface, non sensitive for dirt or contamination,
shows actual values en setpoints, load current, alarms, configuration parameters and
mould memory settings

Power control :
0...100% proportional, zero-voltage switching
Triac rated up to 35A

Automatic soft-start :
(factory defaults)
Powersetting 50% / temperature 120°C / time 1 min
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 Specif ication (cont.)

Sensor-/load-connectors :
24-pole standard-industry female plug 16A/400V
Pin assignment HASCO-norm, other norms available

Accuracy :
0,25% FS

Insulation voltage :
2,5kV mains/sensor circuit

Dimensions :
410 x 367 x 185mm (WxDxH, 6 - 16 zones)
410 x 367 x 345mm (WxDxH, 24 / 32 zones)
410 x 367 x 546mm (WxDxH, 40 / 48 zones)
Additional width of 50mm for heat sink on each side

Colour :
RAL9016 sik gloss : Frontpanel and back
RAL9016 structured : other casing parts
RAL2004 structured : Design element frontpanel

Weight (depending on number of zones)

H1281-6 : 13,7 kg
H1281-8 : 13,8 kg
H1281-12 : 15,3 kg
H1281-16 : 15,5 kg
H1281-24 : 23,9 kg
H1281-32 : 25,7 kg
H1281-40 : 31,4 kg
H1281-48 : 33,2 kg

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 Operations manual H1281

4 Installation and wiring

4.1 Installation
The installation site must provide easy access for the operator without hazard. Suffi-
cient 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
con-troller.
.

4.2 Connection to 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 CEE power outlet foreseen for the
device. If neutral conductor is not wired properly, dangerous voltages can be created
inside the device.
Protective earth conductor must be provided !

4.3 Connection of heaters and thermocouples

Please compare the connecting diagram on the temperature controller (backside, near
the outlet) with the diagram of the mould. Inappropriate connection can destroy con-
troller, 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 24-pol. + PE :

The maximum load capacity of the heater wires (1,5sqmm Cu) depends on the opera-
ting 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 :
1 heater 12,5 A 2 heaters 12,5 A
3 heaters 11,5 A 4 heaters 10,5 A
5 heaters 10,0 A 6 heaters 9,5 A

Load and TC-connection

following HASCO-norm :

Other pin assignment norms available on request.

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 4.4 Alarm- / Standby-connection
For every zone, three 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 2 and 3) as well as one loadbreakage and leakage alarm
(A2, pin 4 and 5).

To activate the 2nd temperature set-point (stand-by function), a 24V DC switching con-
tact is wired to pin 6 and 7. No external power source may be connected to this input.
This function can also be activated manually on the touchscreen.

+24V DC

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 Operations manual H1281

4.5 Casing and functional elements

Front view small casing 6-16 zones :

1 5

1 LED-alarm lighting strip

2 Touchscreen
3 Heatsink (both sides)
4 Fuse holders for load fuses (6 and 8 zones one side, others both sides)
5 USB-data connector

Remark : For the units with 6 and 8 zones, heatsink and fuseholders are only present
on one side of the casing

Back side small casing 6-16 zones :

1 Main switch
2 Mould connectors (6 zones each)
3 Alarm connector
4 Power cord

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 Front view high casing 24-32 zones :

Back side high casing 24-32 zones :

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 Operations manual H1281

Front view triple casing 40-48 zones :

Back side triple casing 40-48 zones :

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 5 Operation
5.1 Main switch

Before wiring the device, make sure that the main switch on the back side of the device
is in position OFF „0“. Herewith, all poles are disconnected from the mains voltage. The
main switch can be locked following EN81-80.
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 retrac-
ting the power cable and securing it against re-connecting or by locking the main
switch with a personal lock.

After having f inished the wiring completely, switch the device on with main switch in
position „1“(EIN / ON) .
Before start-up of the control software, self-test and enabling of controller operation,
power supply to the heating elements is locked and cannot be started.

5.2 LED alarm lighting strip

Above the touchscreen on the front panel of the device, a bright LED lighting strip is
located for a quick information about the operational state of the system and eventual
alarms.

The LED-strip can constantly show red, yellow or green light, which indicates the follo-
wing operational states :

- Red : Alarm is present

- Yellow : Particular operational situation such as softstart, setpoint value not yet
reached or manual powersetting

- Green : Undisturbed operation (see picture above)

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 Operations manual H1281

Safety loadshedding
In addition to both alarms for process-high temperature (A1) and heater failure (A2), a
safety loadshedding function (alarm A0) is wired to the heating masterswitch of the
system. This functions cuts automatically the total heating power of the mould, when a
process-high temperature in access of 50°C is measured somewhere in the mould. This
setting cannot be switched off, it helps preserving the hotrunner and the mould from
damages caused by excessive heating.
In addition to the alarm shown on the touchscreen, the LED alarm lighting strip is illumi-
nated in red.

Before trying to switch ON again the heating main switch, f irst check the whole system
and remove the cause of the excess temperature. Before this excess temperature is not
removed, swiching on the heating again is not possible. On the touchscreen, you can
easily f ind the zone(s), where excess temperature is present.

The alarm limit value A0 can only be altered by an operator with the user rights level
„Administrator“.

5.3 Touchscreen

Operation of the controller is made exclusively by the touchscreen. Therefore, a glass

touchscreen with newest technology, called „projected capacitive“, is used. In opposi-
tion to older touchscreens (with switching f ilm on it), this very sensitive technology re-
quires only a light touch of the screen without any pressure. If there is no reaction of the
system after a light touch input, there must be another reason (e.g. no right of the user
for this specif ic function), pressing more f irmly on the screen does not change the situ-
ation. Operation with gloves may be erroneous depending on the type of glove, in
doubt, take the gloves out.

You can enlarge the screen image with two fingers as you are used to on actual
smartphones or tablet computers („pinch-to-zoom-function“).

To facilitate reading and operation of the touchscreen, the frontpanel of the device (or
its upper part for the higher casing types) is tilted.

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 6 HASCO touchscreen operation system
6.1 Homescreen

The “Homescreen” is the start-up operation screen for all functions and programs of
the HASCO touchscreen operation system, comparable to the desktop of a PC, smart-
phone or tablet computer. From every screen, the “Home”-button will lead you directly
to the homescreen, this button is always on the upper right corner of the screen.

Back Home

The “Arrow” or “Back”-button will lead you to the last visited screen (this can also be
the homescreen, if you just were there).

On the Homescreen, the 6 main functions of the HASCO touchscreen operation sys-
tem can be selected :

Alarms
Analysis
Mould memory
Hotrunner
Mould diagnosis function
Settings

Operation is the most frequently used function, all actual values and conditions are
shown here. Also, the most common inputs and settings are done here.

Thus, this is the most common screen for current operation of the system.

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 Operations manual H1281

6.2 Hotrunner

This button on the homescreen leads you first to the overview of all zones. Here, the
actual situation of all zones is displayed, which gives you a quick impression of the situ-
ation in the mould. So, we strongly recommend you to use this screen during the cur-
rent operation of the controller. All possible situations are shown by different colours,
this permits a quick glance even from greater distance. Zones normally working within
their defined limits without any alarm are shown in green, this should be the current
situation during any operation. In addition to the touchscreen, the actual operational
state of the system is shown by the colour of the LED-alarm lighting strip, see also
chap. 5.2. . Colours on the touchscreen are the same on all menus :
- Green : Undisturbed operation
- Red : Alarm
- Yellow : Particular operation situation : Manual powersetting, measuring zone
or thermocouple linked to another zone

Display actual mould name

Zones overview

Actual mold :

Buttons for Buttons Display Toggle between

common for operational units for operational
functions for display state of state indication
all zones settings all zones all zones

The display field of the actual mould name is also a button to access directly the mould
memory without passing trough the homescreen (see chapter 6.6).

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 In the button array of common functions for all zones, tree functions can be operated :

- Heating ON / OFF :
The heating of all active zones is being switched on or off. When switching on, only
those zones will be switched on, that were active before last switching off.
This function is software based and works only via the touchscreen. If the whole hea-
ting must be switched off into a safe position, e.g. for the wiring to the mould, this must
be done with the main switch on the back side of the unit. This switch is wired to the
main heating power relay of the system and cannot be influenced by the software.

If the heating of all zones is de-activated, the presentation of the heating switch
changes as follows :

- Boost :
For all zones, the boost-setpoint is activated for a limited period of time. This Boost
holding time is hold after the boost-setpoint temperature is reached, then, every zone
goes back to the last operation setpoint.
Boost is being activated for all zones together, and if synchronized heating is active,
also hold until all zones have finished their boost holding time. Slow zones such as e.g.
manifolds may thus delay the whole boost-process in this case, this may be avoided by
choosing boost parameters accordingly.

- Stand-By :
For all zones, the second setpoint (stand-by temperature) is activated as long as until
the operator switches it off again
Activation of Boost– and Stand-By-function is indicated by orange colouring of the
respective button, see example in chap.6.2.2 . If one of both functions is active, the
other one is locked.

Alternative :
„Stand-By“ can also be activated with an external switching contact (see also chapter
4.4).

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 Operations manual H1281

Act./Setpoint

Amps/Powerset.

Toggling of the units in the display of the operational state of all zones can be obtained
by touching the associated field in the lower part of the screen, see above :

- Process value (°C) upper row and setpoint value (°C) lower row, or
- Heating current (A) upper row and powersetting (%) lower row

Example ACTUAL– SETPOINT-temperature :

Zones-Nr. resp. -name (see chap.6.3.4)

ACT-temperature (or heating current of the indicated zone)

Actual operational mode (Auto, Hand, Measuring zone, OFF)

SET-temperature (or powersetting of the heating)

TIP
Group assignment of this zone (see chap. 6.3.4)

With the buttons for display settings, the screen appearance for the overview of all
zones can be adapted :

Number

Text

With the „NUMBER / TEXT“-toggle switch, you can toggle between the number and the
name of all zones. If no name is assigned to a zone, the number of this zone is always
being displayed.

With the „Magnifier“ -button, you can enlarge the display of all zones. In the enlarged
view, actual temperature, setpoint, heating powersetting and -current are being dis-
played (example see next page).
By pressing again the „Magnifier“ -button, you can switch back to the overview of all
zones.

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 6.2.1 Zones-view by group

Zoom overview
Actual mold :

Act. [°C]

Set. [°C]
Amps
Powerset.
Group

Number

Text

With the arrow keys, you can roll through all groups of
zones.

In this screen, all zones are shown in groups of 6 zones with indication for every zone
of
- Actual temperature
- Setpoint temperature
- Heating load current
- Powersetting in % and
- Group assignment .

The colours as well as the buttons are the same as in the overview of all zones.
Operation is made in the detail view (next page), touching of a zone guides you directly
there.

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 Operations manual H1281

6.2.2 Zone detail view

3 2 3 5

4 6 7

1.) Display and altering of ACTUAL- resp. SETPOINT-values

2.) Display name and group of the actual zone
3.) Arrow keys next / previous zone
4.) Display field alarms
5.) ON/ OFF as well as operation mode only for this zone
6.) Settings Boost– and Standby function only for this zone
7.) Buttons zones configuration as well as copy function for inputs

With the arrow keys, you can roll through all zones.

Beside the overview of all zones, this screen is the next frequently used of all. Here, the
most important details of one given zone are shown and can also be operated or mo-
dified. All inputs can be copied with the copy button to one other, several or all zones
(see also page 31).

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 Ad 1.) Display and altering of ACTUAL- resp. SETPOINT-values :

Actual process temperature value Actual Setpoint temperature value,

can be altered, when the display
field is touched (see below)

Setpoint value + or - 1°C

Actual heating current

Actual powersetting of the controller

Entering new setpoint value

Touching of this field opens the following numpad :

Enter the desired setpoint value with the

keyboard and acknowledge with

„Back“ deletes the last digit

„Clear“ deletes the whole number

„ESC“ aborts the entering process, alternatively,

close the numpad with the red cross
(upper right corner)

Attention:
The entered value must be in a range between the indicated „Min“ and „Max“ limit
values, if not, the value will not be accepted.

These limit values are set in the zones configuration menu (see chapter 6.3.4). To
modify them, the operator must at least have the user rights level „Shift leader“.

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 Operations manual H1281

Ad 2.) and 3.) Display name and group of the actual zone, arrow keys

Here, the name of the selected zone is displayed, if a name is assigned. If no name is
assigned, just the number of that zone is shown. Beside the name of the zone, the af-
filiation of a group of zones is displayed. This one can be assigned automatically or
manually chosen, see chap. 6.3.4 zones configuration. The Display field for the zones
name is at the same time a button to alter the the name of this zone without having to
enter the zones configuration (see chap. 6.3.4 ).

With the arrow keys, you can roll trough all zones.

Ad 4.) Display field for alarms :

In the display for alarms, 4 different alarms are being indicated :

Thermocouple alarm Temperature- Leakage alarm

(polarity interchange alarm
or defect) Current alarm or heature breakage

If one of these alarms is present, the respective zone is displayed in red in all screens.
In addition to that, the alarm symbol (bell) on the left side of the alarm display field is
illuminated. Finally, the LED-alarm lighting strip above the touchscreen is illuminated.
Pressing the alarm symbol opens the alarm memory with a list of all actual alarms, see
also chap. 6.7 :

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 Ad 5.) ON-OFF-switch as well as operation mode of this zone :

In this operation panel, you can switch ON and OFF every zone, as well as change their
operation mode as follows :

- Auto : Normal temperature control mode

- Manual (constant) powersetting
- Measuring zone
- Heating OFF

Explanation of the different operational modes :

Control

Auto :
Normal operation of the temperature control. Heating power is automatically adjusted
in a way that setpoint temperature of this zone is reached as quickly as practicable and
then hold precisely. With the intelligent control characteristic, overshot is securely avoi-
ded. No operators action is needed to ensure automatical adaptation („Autotuning“ or
similar).

Manual

Manual :
If the button „Manual“ is pressed,
the following dialogue window
opens :

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 Operations manual H1281

If the displayed powersetting value does not fit the actual need, then press the display
field. Then, the known numpad opens where you can enter the desired value. Close the
numpad with the red cross, the new powersetting value is then displayed.

Attention :
This manual mode de-activates the automatic temperature control, this zone is now
heated with constant powersetting!

Maintaining the desired process temperature must now be ensured by the operator.
To switch back to automatic control mode, press again the button „Auto“ (see above).

Monitor zone

Measuring zone :
If one zone must be operated only as a measuring zone, e.g. if a nozzle is fitted with an
additional thermocouple for enhanced process control, choose the operation mode
„Measuring zone“.
By doing so, the powersetting of this zone is continuously set to 0%, no heating power
is generated.
The associated power outlet at the connector of this zone is not being charged with
heating voltage, but may be bearing high voltage for measuring purpose for short pe-
riods of time.
For another tool, this choice can be switched back again.

Zone OFF

Heating OFF:
The heating power of this zone is neing switched off. Bringing it back into service is
done by choosing again one active operation mode such as Auto, Hand of Measuring
zone. Zones with deactivated heating are not taken into account when total heating of
the device is switched ON or OFF. If a zone with deactivated heating must again be
brought into service, this must be done also in this zone detail view.

The chosen operational mode is indicated by a orange colour in the associated button.
The operational modes „Auto“, „Manual“ and „Measuring zone“ are being indicated in
the overview of all zones by a symbol in the associated zone. This mode can be copied
to another, several or all zones (see page 31).

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 Ad 6.) Buttons for Boost / Standby parameters of this zone :

With these buttons, boost temperature, boost holding time and standby temperature of
this zone can be set.

Boost-temperature :
This parameter is the setpoint for the boost-operation of this zone (boost-function for a
temporary temperature increase). The boostaddition is than added by the system to
the normal operation setpoint of this zone.

Example: Setpoint = 200°C, Boostaddition = 10°C, gives a Boost-setpoint of 210°C

The boost-setpoint is manually activated by choosing the temporary boost via the
touchscreen. Upon reaching of the boost setpoint, temperature is held for a program-
mable time, then automatically brought back to the normal setpoint. The boost-function
is only available during normal operation, not in stand-by operation.
De-activation of the boost is done by entering a boost-addition of „0°C“

Boost time

Boost holding time :

Value in sec.
See “Boost temperature“.

temperature

Standby temperature :
This parameter is the setpoint for the stand-by operation of this zone.

Attention : Setpoint 2 must be entered as an absolute value .

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 Operations manual H1281

Ad 7.) Buttons zones configuration of this zone as well as copy function for entries :

With these buttons, the assignment of this actual zone to a group can be defined.
Furthermore, you can copy data entries made in one zone to others and finally open
the zones configuration with the button „Settings“ (see chap. 6.3.4).

Grouping of zones :
Each zone can be assigned to one of 5 groups :

„Tip“ = Nozzle
„Man“ = Manifold
„A“ = Group A
„B“ = Group B
„C“ = Group C

Pressing the key „Group configuration“ opens the following dialogue window :

Select first on the right side the group, whose zones must be configurated. Then, the
actual zones belonging to this group (if any) are marked green, as well as the name of
the group,

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 Assignment to both groups „Tips“ and „Manifolds“ can be done automatically, if
„Autogrouping“ is selected for each of these groups. This is done depending on the
constantly measured heating current of each zone. When pressing the associated key,
the following dialogue window opens :

Autogrouping

Deselect groups

Threshold Restart
value Auto-
3A grouping

The threshold value for this assigment can be modified by pressing the button
„Treshold value = xx A“, factory default setting is 3,0 A.

When modifying this threshold value, press afterwards the button „Restart auto-
grouping“, this performs the process again according to the new threshold value.

The automatic group assignment can be changed at any time by the operator. Also,
you can de-activate manually the assignment to a group by pressing the key „Suspend
grouping“.

Assigment to one of the 3 manual groups „A“ up to „C“ is arbitrary and shall persist
until an operator changes it again. Assignment to one of the groups is part of the zones
configuration and shall be saved into the mould memory. When loading a set of para-
meters from the mould memory, you don‘t have to redo the group assignment again.

In addition to the name of the zone and the name of the group (might it be as-
signed manually or automatically through „Auto-naming“), you alway have the number
of this zone as a unchangeable indicator.

In all screens showing more than one zone, you always can toggle between name and
number of the zones by using the „NUM“ or „TXT“-toggle switch (see chapter 6.2).

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 Operations manual H1281

Copy

Copy board for parameters or functions :

Newly entered parameters or the ON / OFF - switching of zones can subsequently be
copied to one, several or all zones.
To do this, mark in the copy screen the zone(s), to which the values (or functions) must
be copied (see example below).
This can be done the most easily by choosing a group of zones with the group buttons
on the right side of the screen (marked in red on the picture below). The zones of this
group are then marked in green (see below, zones 1 - 8). This selection can be modi-
fied as needed by touching additional zones or de-selecting zones of the initial group.

The zone from which shall be copied is marked in light colour (see example above,
zone 1). Furthermore, zones switched off are marked in grey (see example above, zo-
nes 9 - 24).

Finally, the group affiliation of all zones as well as zones name, if attributed, are shown.
As in all other screens, toggling between zones number and –name can be done with
the „NUM / TXT“ toggle switch (see also chap. 6.2).

1 2 3 4

5 6 7 8

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 - Copy to one or several zones :
Mark the desired zones and acknowledge with „OK“.

- Copy to all zones :

Press the button „All zones“ and acknowledge with „OK“. You also can de-select
zones by touching them.

- Copy to all zones of one group :

Choose first with the arrow buttons the desired group, then acknowledge with „OK“.

Remark :
Due to the limited space available for the display of one zone, the groups name is al-
ways abbreviated, e.g. „Tip“ for the injectors and „Man“ for the manifold. In the legend
of the copy window, the name of the group is being displayed in full length (example
see previous page).

The copy function can be quit with the „Back“-button (orange arrow) in the upper right
corner of the copy window without copying anything.

Characterist.

Settings :
This key is locked for normal users during current operation, shown (as all locked keys)
by a grey representation. For user with the right level „Shift leader“ or higher, this but-
ton leads you to to zones configuration, see chap. 6.3.4 .

Locked keys guide you directly to the user settings menu (see settings), where you can
choose a user level with more rights. With the „Back“ arrow key on the upper right side,
you get directly back to the screen you saw previously.

Operation of the button arrays „Operational mode“, „Boost / Standby“ as well as

„Settings“ is only possible for operators with user rights „Shift leader“ or higher. If this is
not the case, those buttons are locked, indicated by a grey colour (see example next
page).

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 Operations manual H1281

6.3 Settings

This button on the Homescreen leads you to the functions „Settings“ of the HASCO
Touchscreen Operation System. The extent of the functions available here depends on
the user right level of the operator (see below).
Functions not admitted with the actual user right level are shown in grey colour, see
examples below „System“ and „Zones configuration“.

The actual software version is shown on the right side of the screen, please always
mention it when calling for questions.

6.3.1 User

User

This function leads you to the user management section, tree levels of user rights are
available :

- User (normal operator)

- Setup (shift leader)
- Admin (administrator)

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 The active user at this very moment is shown by a orange representation of the asso-
ciated field (see example above „Administrator“).

After the choice of the desired type of user, a PIN-code must be entered, which can be
specificly defined by an administrator. No specific code being defined, the standard PIN
is „1“ for User, „2“ for Setup and „3“ for Admin .

During current operation, only the levels „User“ and „Setup“ must be used. In the level
„Admin“, additional system– and IT-parameters are accessible, which can stop the
current operation when modified in a wrong way. With lower user right levels, functions
may be locked, indicated by a grey representation, see also page 33.

If the user is logged-in as „Administrator“, two functions are accessible not allowed to
other users :

- Modification of passwords
- Change of the user level when starting the system

Change
Password

Change of passwords :
When selecting this function, the following menu opens, where the password can by
modified for every user right level (see next page). Select first the user right level, for
which the password must be adapted :

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 Operations manual H1281

Choose
Start user

Change user rights at start-up :

When selecting this function, the following menu opens, where the user right level when
starting-up the system can by modified (Factory default = „Operator“).

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 6.3.2 Language

Language

Language

The choice of the actual language is confirmed by an orange frame around the key. All
words in all screens and menus are then adapted accordingly. The active language is
also shown on the upper right side of the homescreen (see chapter 6.1).
Adapting the active language is allowed in all user levels

Available languages fill several pages on the screen, toggle between them with the
arrow keys.
.

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 Operations manual H1281

6.3.3 System

Settings in this menu concern mainly the memory settings, furthermore, additional
parameters can be set, that only must be modified by the manufacturer.

This function is only available in the level „Admin“.

Date /
Time

- Date-/ Time setting :

The date-/time setting is an operating system function of the industrial computer used
in this unit, all time relevant program functions use it. This is of particular significance
for functions with date / time stamp such as e.g. the alarm history. If the system time is
changed, e.g. as the unit is placed in another time zone of the world, all new system
entries get then the new system time. Please take that fact into account when analy-
sing time sensitive events.

When pressing the „Date-/timesetting“-key, the following dialogue appears (see next
page) :

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 Please select from the pull-down menues „Continent“ and „City“ the ones, that come
most close to the actual location of the system. Then enter the actual values for date
and time by pressing the relevant data field. By doing so, the already known numpad
opens, enter the desired numbers and close the numpad with the red cross.

Finally, quit the dialogue with the red cross.

Sensor
Type

- Temperature control - sensor type :

When pressing the „Sensor type“-key, the following dialogue appears :

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 Operations manual H1281

Thermocouples type „J“ (Fe-CuNi) or „K“ (Ni-CrNi) can be selected. In case of thermo-
couples type „J“, you may also choose between an upper limit of the measuring range
of 400 or 800°C.

Attention :
When changing the type of thermocouple („J“ or „K“) , the internal wiring of the control-
ler must be adapted to the right compensation wires. If this is not done, signal proces-
sing of the sensor data is false and will lead to an erroneous temperature control.

- Software-Update :
With this function, the complete program software of the controller can be updated.
This function is only accessible for users with the user right level „Administrator“.

The update is definite, this operation cannot be withdrawn without additional actions.

If the update is not successfull or if the new software does not fullfill the expectations of
the user, a previous software version must be installed by another software update.

Attention :
It is highly recommended to perform a software update only in close collaboration with
the manufacturer, e.g. during a conference call.

Procedure :
To perform a software update, you need to prepare first a functional upgrade data file
on an USB memory device. This data file is normally provided by the manufacturer of
the device and needs to be adapted exactly to the actual control system, e.g. number
of control zones, eventual options and hardware-specific particularities (e.g. touch-
screen drivers).

Updates with unappropriate data files, e.g. from similar but not identical devices or
corrupt data files with later modifications, may cause total failure of the device !

The USB memory device must first be connected to the USB-data port on the front
panel of the device (see chapter 5.2).

HASCO hot runner 39

 Then, press the key „Software update“ in the system menu (see overview on chapter
6.3.3). When doing so, a confirmation menu appears, that needs to be acknowledged
by pressing the „OK“ key :

Software - Update

Do you want to update

now ?

If you want to abandon the update for whatever reasons, leave the menu with the red
cross.

The „OK“ key is only enabled, if a functioning USB memory device is recognized on the
USB data port on the front panel. Otherwise, the key is shown in grey and cannot be
operated :

Software - Update

Do you want to update

now ?

If a functioning USB memory device is connected and recognized and the „OK“ key is
operated, but no appropriate program data file is found, another warning menu ap-
pears :
Software - Update

Do you want to update

now ?

No update file found !

When all functional requirements are fulfilled, the complete software update process is
now executed automatically, afterwards, the system is operational without any further
action by the operator / administrator.

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 Operations manual H1281

Control parameter

- Temperature control configuration :

Temperature control of your HASCO unit is fully automatic, that means with automatic
adaptation to the characteristics of every connected heating zone. In rare cases of very
unusual behaviour of an heating zone, this automatic adaptation can be switched off.
You may then choose from three auxiliary control programs to ensure a stable produc-
tion process.

This manual override of the control configuration must only be used in particular cases
and with previous consultation of the manufacturer of the unit.

When pressing the „Control configuration“-key, the following dialogue appears :

For normal control operation, „Automatic“ must be selected. Is this done, the auxiliary
control program „Mode 1“, Mode 2“ or „Mode 3“ actually selected by the system is
displayed, both by a orange colour of the key.

If „Automatic“ is disabled and one of the three auxiliary programs is manually activated,
no automatic adaptation of the control to the heated zone takes place anymore.

The manually selected mode stays active as long as it is changed manually, even if
another tool was wired to the unit in the meantime.

HASCO hot runner 41

 The number in the data field „Delta-T“ must be „10“ and must only be modified by the
manufacturer of the unit.

The configuration data as described above are only valid for one single zone. They may
be copied as all other data entries to one, several or all other zones as described on
page 31.

- Unit change °C / °F:

To change the unit of all temperature values, press the button „°C / °F“. The following
dialogue menu ones :

All temperature values, also setpoints in the mould memory, are automatically transfor-
med into the respective other unit and displayed accordingly.

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 Operations manual H1281

- Back-Up mould memory :

You can make a safety back-up of the total content of the mould memory on an USB
memory device.
We strongly recommend to perform a complete back-up by the system admini-
strator on a regular basis and to store the USB-memory device away from the
controller in a safe place or to perform another back-up routine also for this memory
device.

Not doing this means a total loss of mould data in the case of a damage of the control-
ler (e.g. fire or damage of the internal memory device), so all mould data must then be
re-entered manually.

For data saving on an external memory device as well as re-loading the mould memory
from this device, the following menu is used (see also overview in chapter 6.3.3):

Mould memory

Mould memory

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 - WIFI-operation of the device :
All devices are equipped with an own WiFi transmitter / receiver. Beside the other
functions, WiFi access data to the device as well as the webpage name (URL) are
displayed on the left side of the screen (see chapter 6.3.3).

Operation of the system can be remote controlled from every WiFi-equipped external
device (smartphone, tablet or so) with an internet browser. No applet or program
download is required. The connection is not made via the internet, but by a safe peer-
to-peer WiFi connection between participating devices. The number of devices is un-
limited, you can operate from several devices at the same time.

To connect to the system, proceed as follows :

1. Log in at the systems own WiFi :

Switch your device to the „Settings / WiFi“ page, check for available networks.
Now, it must show the network name displayed on the left side of the HASCO
screen, in the example shown here above, it is „HASCO_WLAN“. Then enter the pass-
word shown there as well, in this example „HASCO2020“ and press „connect“ on your
device. A warning „No intenet connection on this network“ or so may be shown. The
range is appr. 15m depending on local conditions.

2. Selecting HTML-page :
The easiest way to do so is to scan the QR-code shown on the HASCO screen and
press „Activating link“, „Connecting“ or so on your device. With newer devices, a QR-
code scanner is integrated into the camera. If not, download an appropriate QR-code
app from your appstore.
If no QR-code scanner is present, you may also enter the URL directly on the webpage
line of your internet browser. Functions of several browsers may be different, in doubt,
choose another browser.

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 Operations manual H1281

6.3.4 Zones conf iguration

In the zones configuration, mould and/or production order specific parameters of the
controller system can be set, that typically do not have to be changed during current
operation. All parameters of all zones can be stored in the mould memory and easily
reloaded during the next use of that same mould.

Access to the zones-configuration is only possible for user rights from level „Set-up /
shift leader“ and higher.

1 4

3 2 6 5

1.) Display zone number and -name, arrow keys

2.) Altering zones name and Autonaming
3.) Function group configuration : Setpoints, grouping as well as copy function
4.) Function group heating : Softstart, guided and sequencial heating
5.) Thermocouple failure operation
6.) Alarm configuration : Load shedding-, temperature-, current– and leakage alarm

The entry of data described here is valid for the zone named on top of the screen. If
those data must become valid for several zones, use the copy function as described in
the detail view of one zone.

With the arrow keys (see above), you can roll trough all zones.

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 Ad 1.) Display field zone name and –group, arrow keys :

Here, the name of the selected zone is displayed, if a name is assigned. Display and
functions are identical with the screen „Zones detail view“, see chap. 6.2.2 .

Ad 2.) Zones name and Autonaming :

Change
name

- Manual entry of a name for a zone :

When pressing this button, an alphanumerical keyboard opens. After having typed the
desired name or number, save with .

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 Operations manual H1281

Remark1 :
Toggling between capitals and lower cases can be done with the „shift“ key. If lower
case letters are activated, you can also enter numbers with the upper line of keys.

Remark2 :
To ease the entering of names, a „quick choice“ menu with frequently used names (tip,
manifold etc.) can be used. After having chosen the desired name, acknowledge with
„Confirm“, this name appears then in the entering field. To complete this generic name,
just enter other letters or numbers with the keyboard and close with .

Autonaming :
The „Autonaming“-function saves the time and effort needed to manually number a
greater number of zones, whose names shall only differ by a consecutive number.

Example :
Manifold to be numbered continuously from „Man 1“ up to „Man 4“

To do so, enter first a the name without number, as described previously. For common
names, use the „quick choice“ function.

The name, that all zones shall have in common, must be given to the first zone in the
row, which then will be number 1.

Press then the Autonaming“ button, which opens the copying field known from other
copy procedures in the zone detail view. Mark all zones, which must be part of that
numbered row (see following page).

HASCO hot runner 47

 Here, you can select randomly all zones, that you want to be numbered. For the selec-
tion or de-selection of zones, proeceed as for all other copying processes, see also
page 31. The zone, whose name shall be used for the autonaming of the whole row, is
indicated on top of the screen window. You also can skip zones, which are part of
another group, eg. manifolds, headers, bushings etc. .

Acknowledge with the -button, then the autonaming of the row commences,
starting with number „1“. The order of the numbering cannot be changed.

Ad 3.) : Function group configuration

Setpoints

Editing „Setpoints“ :
When pressing this button, the following dialogue menu opens, where additional set-
points accessible only for users from „Shiftleader“ level on can be set (see next page) :

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 Operations manual H1281

- Setpoint 1 - Operation :
This parameter is the setpoint for normal operation of every zone, it is the only one of all
parameters shown here that can also be changed by a normal operator with the user
rights „Operator“ in the detail view of this zone.

- Setpoint 2 - Stand-By :
This parameter is the setpoint for the stand-by operation of this zone.

Attention :
Setpoint 2 must be entered as an absolute value .

- Setpoint 3 - Boost-temperature :
This parameter is the setpoint for the boost-operation of this zone (boost-function for a
temporary temperature increase). The boostaddition is than added by the system to
the normal operation setpoint of this zone.

Example: Setpoint = 200°C, Boostaddition = 10°C, gives a Boost-setpoint of 210°C

The boost-setpoint is manually activated by choosing the temporary boost via the
touchscreen. Upon reaching of the boost setpoint, temperature is held for a program-
mable time, then automatically brought back to the normal setpoint. The boost-function
is only available during normal operation, not in stand-by operation.
De-activation of the boost is done by entering a boost-addition of „0°C“

Boost holding time :

Value in sec.
See “Boost temperature“.

HASCO hot runner 49

 - „Higher-“ and „Lower setpoint limit“ :
Max. allowable range for setpoint 1 to be entered by an operator. The actually active
limits are shown on the num-pad during the entering process. Setpoints outside this
range are not accepted (see page 24).

- Power setting limitation :

Value in %
Limitation of the power setting is only required for a too high heating power installed in
this zone (e.g. heater with the desired dimensions only available with higher power).
Nomally, power setting limitation is out of order (setting: 100 %).

The power setting limitation can also be used to limit the required mains power, eg. if
only a power outlet of a lower wattage is available. In this case, it is normally sufficient
to limit the power setting of the high output zones (eg. manifolds).

The required duration for heating up the mould increases linearly with limiting of the
power setting, that‘s why using this method must only be done in particular cases.

Groups

„Group configuration“ :
When pressing this button, the group configuration menu opens, which can also acces-
sed from the zone detail view by users with the right level „Shiftleader“. Description see
chap. 6.2.2. .

Copy

Copy function for data entries :

Just as in the zone detail view, you can also use the copy function in the zone configu-
ration menu to copy data entries or settings from one zone to another, several or all
other zones. Description see chap. 6.2.2. .

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 Operations manual H1281

Ad 4.) : Function group heating

Softstart-Settings :
When pressing this button, the following dialogue menu opens, where you can edit the
softstart settings of the actual zone :

Softstart-duration : value in min

Softstart-powersetting : value in %
Softstart-setpoint : value in °C

Softstart with those indicated values is only effective for this zone, if the button
„Softstart preselected“ is activated, shown by an orange colour of the button (see
example above).

General remarks about softstart :

During the softstart, the controllers output response is limited to a preselected
softstart powersetting, in order to achieve a slow baking out of high performance hea-
ting 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.
Softstart is only activated for the first heating after start-up of the device, if the actual
temperature is < 80°C. If the actual temperature is > 80°C, no softstart is performed,
but the system starts heating only after 1min delay time.

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 The softstart can be activated and programmed for every zone individually. De-acti-
vation of the soft-start is done by pressing again the „Softstart preselected“-key (button
couloured white) for this actual zone .

Setpoint 1

Softstart-
Setpoint

Softstart-powersetting Softstart-
duration

Sync.heating

Synchronized heating :
With the function „Synchronized heating“ active, all zones are heated up together, this
means that all zones reach the same temperature at approximately the same time. This
avoids that quick zones (e.g. the hot tips) reach their setpoint temperature much earlier
than slower ones (e.g. the manifolds), which could cause „baking“ of the material in the
tips or even a damage of the hotrunner system.

If there is a big difference in heating power between tips and manifold and / or a very
temperature-sensitive material, use in doubt always this function. Also, take into ac-
count the recommendations of the hotrunner manufacturer

The duration of the total heating process depends on the slowest zone, it can take up
to 30min for some moulds.

This setting is valid for all zones together.

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 Operations manual H1281

Man.sequence

Sequential heating :
If step-by-step heating-up of the hotrunner is needed instead of the synchronized start-
up, you can define a sequential heating up. After pressing the associated key in the
zones configuration menu (function group heating), the following window opens :

Up to 3 groups of zones can be heated up one by one. Every group is heated until a
predefined temperature is reached, then waits for a given delay time (if set), then the
next group starts its heating in the same manner.

The desired groups for sequential heating-up must be defined prior to setting up the
heating sequence, see „zones configuration - Parameter - Autogrouping“. Typically,
heating-up of manifolds and tips is separated. If more groups must be defined (e.g.
spruces), use the free groups A, B or C.

Setting up a heating sequence is done step-by-step from left to right (see next page) :

HASCO hot runner 53

 1. Entering the holding temperature for the first group

2. Entering the holding delay time for the first group

3. up to 5. : Entering those parameters similarily for the 2. group.

For the 3rd. Group, only the holding temperature needs to be set.

To finish, activate the sequential heating up by pressing the button „Sequential heating
active (lower side, see previous page), this is confirmed by an orange colouring of the
button. Then, quit the window with the arrow key.

After having executed the sequential start-up, all zones are heated until their respective
setpoint temperature is reached.

Ad 5.) Thermocouple failure operation :

In this sub-menu is defined, how the system must react in case of a defect thermo-
couple. By pressing the associated key, the following dialogue opens :

„OFF“ :
When thermocouple failure occurs, an alarm is given in the detail view of this zone,
„Thermocouple failure“ is indicated, see also chap. 6.2.2 . The heating power is shut
OFF, that means constantly set to 0%, but remains in operation mode „Auto“.

„Manual“ :
When thermocouple failure occurs, this zone is set to operation mode „Manual“.
Heating remains active, but is now operating in manual mode with constant powerset-
ting. By pressing this key, the following dialogue opens (see next page) :

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 Operations manual H1281

When touching the display field for the powersetting, the known num-pad opens auto-
matically, please enter the desired value. Close the dialogue with the arrow key, the
value of assigned manual powersetting is now shown in the display.

Attention :
This zone is now heated with constant powersetting, maintaining the desired process
temperature must now be ensured by the operator.

Reference
zone

„Coupling“ :
When thermocouple failure occurs, this zone is coupled to another one with working
thermocouple. By pressing this key, the following dialogue opens :

To activate coupling, touch the display field „Zone“ antippen, enter the number of the
reference zone with the known numpad and confirm with the „Arrow key“.

HASCO hot runner 55

 Attention :
By coupling the actual zone to another one, it will be heated with the powersetting oth
the leading zone to which it was coupled !

Thus, coupling of a zone makes only sense if both zones have similar characteristics
and are located close to each other. Finally, close the dialogue with the red cross, the
actual process temperature value of the reference zone is then displayed for the
coupled zone in the zone overview as well as in the zone detail view.

To de-activate the coupling, select another mode in the „Thermocouple failure opera-
tion“-menu.

The actually active mode for „Thermocouple failure operation“ is indicated by an

orange coulouring of the respective button in the menu. The same is true for the cho-
sen mode within the function group „Heating“ :

Manual

Ad 6.) Alarm configuration

Safety alarm

In this menu bar, the different alarms of the controller can be configurated:

Load shedding alarm :

When pressing the key „Load shedding alarm“, the following dialogue menu opens (see
next page) :

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 Operations manual H1281

Safety alarm

When touching the display field for the alarm limit value, the known num-pad opens,
where you can enter the desired new limit value. The actual value is displayed in the
field and will be updated after the modification. The limit value is added to the actual
setpoint value :

Example:
Setpoint Zone 1 = 200°C , Limit value = 50°C°, means load shedding at 250°C

After having finished, close the menu with the red cross.

Attention :
The safety loadshedding alarm (total heating switching off at high temperature in the
mould) can only be altered for operators with user right level „administrator“, see also
description on page 17.

For all other users, the key is locked, see also example on page 33.

Temperature

Temperature alarm :
When pressing the key „Temparature alarm“, the following dialogue window opens :

Limit above setpoint °C

Limit below setpoint °C

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 The upper and lower alarm threshold value can be activated and set separately. Alarm
limit values are always relative to the active temperature setpoint. Activation of each
alarm is indicated by an orange colouring of the respective button (Exemple see pre-
vious page, lower and higher alarm are active).

When pressing one of the keys „Upper limit value“ or „Lower limit value“, the known
num-pad opens, where you can enter the desired new limit value. The actual value is
displayed in the field and will be updated after modification.

With the key „Signal inverted“, the switching behavior of the alarm relay for the external
alarm output (chap. 4.4, see page 12), the actual state is shown by an orange colou-
ring of the button. If the output is inverted, the alarm relay is then closed if no alarm is
present. This type of signal is needed for some injection presses for release of the pro-
cess.

All temperature alarms of all zones are operating the common alarm A1, which is wired
to a floating contact on the alarm connector on the back of the device, see chapter
4.4 .
Is the temperature alarm configurated as a range alarm or low temperature alarm, the
common alarm A1 can be used for production release of an injection press. Depending
on the type of switching contact of the press, the alarm might need to be inverted, see
examples previously described.

After having finished the limit value entry, quit the menu with the red cross and get
back to the „zone configuration menu“.

Amps

Heater current alarm :

When pressing the key „Current alarm“, the following dialogue window opens :

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 Operations manual H1281

When pressing again the key „Current alarm“, the known numpad opens, where you
can enter a modified current alarm limit value. The actual limit valueis displayed in the
field and updated after modification.

The current alarm value is a low limit alarm, that means alarm is given when actual hea-
ting current descends below the limit value.

With the key „Signal inverted“, the switching behaviour of the alarm relay for the exter-
nal alarm output can be inverted as previously described. The actual state is indicated
by an orange colouring of the key.

Leakage

Leakage alarm :
To monitor the actual powersetting of all active zones, a maximum alarm powersetting
(in%) can be set. If this alarm threshold value is reached in one or more zone(s), lea-
kage alarm is switched.
All leakage alarms of all zones are operating also the common alarm A2, as does the
heater current alarm, which is wired to a floating contact on the alarm connector on
the back of the device, see explanation above.

When pressing the key „Leakage alarm“, the following dialogue window opens :

When pressing again the key „Leakage alarm“, the known numpad opens, where you
can enter a modified powersetting limit value. The actual limit value is displayed in the
field and updated after modification.

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 General remarks on leakage alarm :
Setting a leakage alarm threshold value makes sense mostly on tip zones to detect a
„drifting“ of the heating powersetting above the average value on a longer operation
period. Such a drift of the heating power setting can be caused by a leakage of molten
plastic, e.g. on the junction of the nozzle and the mould cavity that‘s why this alarm is
called „Leakage alarm“.

As operation conditions on the nozzle heating differ from case to case, automatic deter-
mination of the average powersetting is dangerous, it bears the risk to create false
alarms or, on the other hand, to not detect leakage situations.

That‘s why the leakage alarm threshold value must be determined manually, e.g. by
observing the average heating powersetting for a duration of about one hour under
comparable operation circumstances.

Rule of thumb : Dubble the average powersetting

Example :
Heating powersetting tip zones : 5...10%
Recommended alarm threshold value : 20%

For detail observation of the heating powersetting, it may be wise to use the realtime
analysis function (see chapter 6.5).

Short-term exeeding of the powerseting is not taken into account, as well as exeeding
at first heating-up of the hotrunner or at setpoint changes.

The leakage alarm does not influence the actual control behaviour, that means the
alarm threshold value does not limit actual heating powersetting. If this shall be done, a
powersetting limitation can be set, see chapter „zones configuration - setpoints“

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 Operations manual H1281

6.4 Mould diagnosis

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.

The mould diagnosis is a separate function of the HASCO controller and can only be
performed outside current operation.

The continuous heating is switched off, no production can be run during mould diag-
nosis.

For this reason, a warning menu appears after selection of the mould diagnosis, which
must be acknowledged.

After acknowledgment, the status-screen of the mould diagnosis is shown :

1 2 3 4 5 6

7 8 9 10 11 12

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 Attention :
During the mould diagnosis, a weak heating pulse is subsequently given on every zone,
then the temperature increase on that zone is checked. This is done at low temperature
(max. 120°C), so that normally, no cooling device is required (only for very delicate
moulds).

With a standard mould configuration, the diagnosis can immediately be engaged with
the „Start“-button. Progress of the diagnosis is shown by the coloured marking of every
zone with the result (normally green). If there are still zones left in white, the diagnosis is
not finished yet.

Attention :
As all zones are checked separately one by one in several steps, the whole diagnosis
can take up to half an hour, in exceptional cases even longer.

After start-up of the diagnosis, no input is required, the presence of an operator is not
necessary. Ongoing execution of the diagnosis is shown by a running symbol (rotating
star, lower right corner).

When the mould diagnosis is finished successfully, the result is shown as follows :

1 2 3 4 5 6

7 8 9 10 11 12

Diagnosis
ongoing

In the „Normal view“, the result for each zone is depicted with a colour, a legend on the
right side of the screen explains them.

For more information about the analysis result in one particular zone, press the field of
this zone, the following window then shows up (see next page) :

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 Operations manual H1281

Diagnosis result :
1 2 3 4 5 6
Testing time Remaining
7 8 9 10 11 12

Result :

Thermocouple interchanged with zone 8

This can also be done during the current analysis to follow its progress. The pre-set
diagnosis time is count-down, as soon as the sensor is detected, diagnosis for this zo-
ne stops and the next zone is taken.

Alternatively, the result can also be shown as a table, press „Enhanced view“ to do so
(button see previous page) :

Diagnosis
ongoing

The „enhanced view“ gives immediately the result for every zone with a symbol, but
depending on the total number of zones, you must use the roll bars on the right side to
see all zones. Also in the enhanced view, you can access the detail result by pressing
the associated zone field (see above).

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 Operations manual H1281

The diagnosis result of each heater can be shown altenatively as heating power (W),
current (A) or resistance (Ohm). To switch from one unit to another, press the column
title „W / A / W“ and choose the desired unit (menu see below). Afterwards, quit the
menu with the red cross.

Display

In both views, you can download the result as a csv-file via USB-interface.

Download
result

The csv-file created this way can be opened, edited and saved on every office-pc with
all current spreadsheet– or database software programs (example below shows zones
1 - 10) :

Mould diagnosis-05-10-2020-16-02-21
Zone Name Power [W] Status Result
1 Nozzle 1 275 OK
2 Nozzle 2 275 OK
TC interchanged with
3 Nozzle 3 275 defect Zone : 4
TC interchanged with
4 Nozzle 4 275 defect Zone : 3
5 Bushing 575 OK
6 Manifold A 2575 OK
7 Manifold B 0 defect Thermocouple
8 8 275 OK
9 9 275 OK
10 10 275 OK

The memory device is connected via the USB-port on the front of the device.

Attention:
Given the USB interface definition, any USB-port is hasardous as well from the hard-
ware- (EMV) as from the software standpoint. Please consider this when defining rules
of access to the unit.

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 6.5 Real time analysis

With the real time analysis (tracing function), the evolution of important control para-
meters with time can be shown and analysed as a diagram.
Here, first the parameters

- Setpoint
- Proces value (actual temperature) and
- Powersetting (heating power)

are shown for all zones as bargraphs :

If the control behaviour of a given zone shall be analyzed in detail, pressing the „zone“
button opens a curve showing that zone (see next page) :

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 Operations manual H1281

With the arrow keys (left and right of the zone number), you can scroll through all zo-
nes.

Toggle between process value, setpoint and powersetting by pressing the respective
button underneath the zone number field. For an enlarged view of the curve, use the
„Pinch-to-zoom“ function, see chap. 5.3)

By pressing the button (upper right side), you get back to the overview of all
zones.

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 Operations manual H1281

6.6 Mould Memory

With the mould memory, all parameters of all zones can be stored to be reloaded if
this mould is re-used for the next time in production.

The first position in the mould memory is always „Factory default / RESET“, this mould
can not be altered or deleted. Here, all standard parameters are stored, an average
mould should work at first instance with those settings.

HASCO Mold 1

HASCO Mold 2

HASCO Mold 3

Another position is taken by the actual BACK-UP. This is created automatically by the
system and updated every 5 minutes without any intervention of the operator. It is al-
ways loaded when restarting the system.

Attention :
When a mould is loaded from the memory (also the default settings), all actual para-
meters are overwritten and so, lost. If you have found an actual set of parameters by
trials, save them first as described below as a different mould (new name).

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 Storing a set of parameters :
With the button „Save new mould“, a menu opens where a neutral name („New Tool
Nr. xxx“) is proposed.

This name can be used to save the set of parameters, but also any other name. To
change the name, hit the button with the name field. Enter the desired name for the
new mould as already described for the zone name (see page 46) and close the menu
with the red cross.

Keyboard

Loading a set of parameters :

1. Choose the desired mould (the name is then marked in ORANGE)

Mold data set

Werkseinstellung - Reset

H1281 - Backup

HASCO Mold 1

HASCO Mold 2

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 Operations manual H1281

2. Press „Loading mould“

Attention :
When loading a new mould or activating the factory default settings, all actual para-
meters and settings are overwritten and lost. The loading process starts immediately
after the button is hit, no confirmation is asked.

Overwriting a set of parameters :

1. Choose the desired mould (the name is then marked in ORANGE)

2. Press „Replacing mould“ (see above)

3. Acknowledge with

This function must only be used, if the stored data saved under this name will certainly
not be needed anymore. If they might be usefull at a later moment, you better store the
actual version under a new name (eg. mould xxx version 2 or so).

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 Deleting a set of parameters :

1. Choose the desired mould (the name is then marked in ORANGE)

2. Press „Deleting mould“ (see previous page)

3. Acknowledge with

Attention :
Deleting a mould from the memory removes all associated parameters and settings
irrevocably.
The factory default / RESET values can‘t be removed or overwritten.

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 Operations manual H1281

6.7 Alarms

With the program „Alarms“, all actual and previous alarms can be checked.

After having choosen the program, a list of all actual alarms appears first. If an alarm
dissappears (problem solved), this alarm is also automatically deleted from the list.

To view all alarms, also the previous ones, press the button „History“ below the list (see
above and next page). This choice is confirmed by an orange colour of the button.

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 Alarm

Phase L1 is missing

Phase L2 is missing

Phase L3 is missing

Temperature alarm zone 1

Current alarm zone 1

Temperature alarm zone 2

Current alarm zone 2

Log

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 Operations manual H1281

7 Key word index

Thema : Seite :

A Actual process temperature………………………..………………. 21 - 24

Alarm configuration………………….……………………………… 56
Alarm connector…………………..……………………………….. 12
Alarm de-activate (temperature)………………………………….. 57 ff.
Alarm history…………………………..…………………………….. 71
Alarm limit values…………………………………………………… 57 ff.
Alarm range……………………….………………………………... 57
Arrow keys………………………………………………………….. 23, 25, 45,
46
Automatical grouping of zones………………………..…………… 29 - 30
Autonaming (automatical numbering of zones)…………………... 47

B Backup mould memory…………………………………………….. 43

Boost-function………………………………………...…………….. 20

C Copying of data entries…………………………………………….. 31

Control configuration (Temperature control)..………………….…. 41
Coupling of a zone - see leading zone ………………….………… 55
csv-data file………………………………………………………….. 64
Current alarm………………………………………………………... 25, 58
Curve tracing - see real time analysis…….………………………. 65

D Data export…………………………………………….……………. 64

E Export result mould diagnosis…………………………………….... 64

H Heating current……………………………………………...……… 21 - 24
High temperature alarm - see temperature alarm….…………..…. 25, 57
Homescreen………………………………………………...………. 18

K Key lock - see user rights…………………………………………... 33

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 7 Key word index (cont.)
Thema : Seite :

L Leading zone - see coupling of a zone………………….………… 55

Leakage alarm………………………………………………………. 59
Load fuses…………………………………………………………... 9, 13 - 15
Low current alarm - see current alarm…..……………………...…. 25, 58

M Mains connection………………………………………….………... 11 - 13
Manual operation………………………..…………..……………… 26, 54
Measuring zone………………………………………………..……. 27
Mould connection cable…………………………………………….. 11, 13 - 15
Mould diagnosis…………………………………………………….. 61 ff.
Mould data - load……………………………………………………. 68
Mould data - delete…………………………………………………. 70
Mould name - change…………………………………………...…. 69

P Password - see user rights……………………………………..…… 34

Password - change…………………………………………….……. 35
PIN-Code…………………………………………………………….. 34
Powersetting control zone………………………...……………….. 21 - 24
Powersetting limitation…………………………………………….... 49 - 50

R Real time analysis…………………………………….…………….. 65

Reference zone………………………...………………………….… 55

S Sequential heating up………………………...…………………….. 53

Safety loadshedding……………………………………………….... 17
Setpoint - temperature zone……………………………………..…. 21 - 24
Setpoint limitation…………………………………………………… 49 - 50
Single zone view.………………………………………….………... 23
Softstart……………………………………………………………… 45, 51
Software-Update……………………………………………………. 39 ff.
Software - version number…………………………………………. 33
Standby………………………………………. …………………...… 20
Synchronised heat-up - see zones synchronisation...…………….. 52

T Temperature alarm………………………………………………..… 25, 57

Temperature unit switching °C / °F………………………………… 42
Thermocouple failure operation…………………………..………... 54
Touchscreen…………………………………………………………. 13 - 15, 17
Touchscreen cleaning……………….……………………………… 6

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 Operations manual H1281

7 Key word index (cont.)

Thema : Seite :

U Update - see software update..……………………………………. 39 ff.

USB-connector………………………………………………………. 13 -15
USB-export…………………………………………………………... 43, 64
User rights..…………………………………………………………. 33
User rights at system start-up……..………………………………. 35

W Wifi-operation of the system (remote control)……………….……. 44

.
Z Zones - configuration………………………………………………. 45
Zone - copying parameters.……………………………………….. 31
Zone - coupling to another.………………………………………… 55
Zone - enter name………………………………………………….. 46
Zones - group view…..……………………………………………... 22
Zone - switching on/off (single).……………………………….…… 26 - 27
Zone - switching on/off (all)…...……………………………….…… 20
Zones synchronisation - see synchronised heat-up…………..…. 52

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 8 CE-conformity certif icate

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

Model designation : Multizone-Temperature controller

Type : H1281/06 up to H1281/48

Hereby is confirmed, that these products meet in their design and ac-
complishment as marketed by the manufacturer and if properly used
the following EU-directives :

EU-Low voltage directive 2014/35/EU

EU-Directive for electromagnetic compatibility 2014/30/EU
EU-Directive for limitation of hazardous substances
in electric and electronic devices (RoHS) 2011/65/EU

Applicable harmonized norms : EN 60204 Part 1

EN 61000-6-1
EN 61000-6-3

This declaration is binding for the distributor

HASCO Hasenclever GMBH + Co. KG

Römerweg 4, D-58513 Lüdenscheid · Germany

Lüdenscheid, 01.10.2020 Florian Larisch

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Built to Control.
05 21 1 i
© by HASCO Hasenclever GmbH + Co KG
Postfach 1720, D-58467 Lüdenscheid
T +49 2351 957-0, F +49 2351 957-237
info@hasco.com, www.hasco.com

Subject to technical modifications.

Please always check all the data against the
product information we publish on the internet.