D-M-E Smart Series. Temperature Controls For Hot Runner Molding Systems

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1 D-M-E Smart Series Temperature Controls For Hot Runner Molding Systems

2 Advanced Temperature Control for Hot Runner Systems Capability D-M-E offers -, -, -, and -zone standard mainframes for A operation and -, -, -, and -zone standard mainframes for 0A operation. Components listed in this catalog satisfy all international compliances. Three - Year Warranty All D-M-E temperature controllers are now covered by a three - year warranty, excluding fuses and triacs. Electrical Noise Immunity To enhance immunity from electrical noise, power and thermocouple wires are harnessed in separate wire ways within the body of the frame. Additional noise immunity is provided through the use of shielded thermocouple wires. The D-M-E Smart Series is the result of intensive and dedicated research with a goal of designing today s most versatile and reliable line of temperature controllers. D-M-E achieved this goal by not only incorporating the latest technology, but by also making certain that each controller is easy to install and above all... easy to operate. Heavy Duty Welded Construction With years of experience behind its design, the Smart Series line is built to last under the most rigorous conditions. The mainframe's welded gauge steel construction ensures long life and peak performance. Cooling fans in the frame are strategically located to increase air ventilation, maintain cooler running conditions, and promote control module reliability.

3 CE COMPLIANT! D-M-E Mainframes and Modules Comply with Electromagnetic Compatibility and Low Voltage Directives Control Modules SSM ( and 0 AMP): The SSM module provides accurate temperature control, including Smart Start heater dry out circuitry, thermocouple fault displays and auto/manual modes of operation. The SSM features automatic or manual bumpless transfer which, in the event of a thermocouple fault, provides switch over to manual mode at the proper power setting to continue molding until the fault can be corrected. This module can also trigger remote standby heat (idle), boost, off, and alarm functions when used with the TAS module. DSS ( and 0 AMP): For those who require independent dual displays for process and setpoint temperatures, the DSS is the ideal choice. The DSS module also features automatic or manual bumpless transfer. This module is also fully compatible with the TAS module for standby heat and alarm functions. SSM--0 CSS ( and 0 AMP): The top of the Smart Series line, the CSS module is full featured and provides excellent closed loop control. The CSS also works in conjunction with the CIM computer interface module. With an SPI protocol-compatible molding machine, setpoint temperatures can be set and system operation can be monitored via the machine control panel. The CSS module also has automatic or manual bumpless transfer and can be paired with the TAS module. Accessory Modules TAS: The TAS module provides over/under visual and audible alarms, boost, and standby heat control with control modules as stated above. The TAS module can accommodate up to zones of control. Alarm is activated at ± 0 F. See pages - for details. CIM: The CIM Computer Interface Module is the communications link between CSS modules and a remote host system. The CIM module can accommodate up to zones of control. See page. NOTE: Both the TAS and CIM accessory modules require the use of MFC style communications mainframes. Non-communications frames may be upgraded on-site with installable kits. DSS--0 Simplified Power Hook-Up CSS--0 Concern for user convenience didn t stop with improved operation features. D-M-E went one step beyond to ensure that the power hook-up procedure goes smoothly as well. For this reason, detailed schematics for various hook-ups are provided directly on all mainframe back panels. If it is ever necessary to change the configuration, these diagrams will help ensure safe and proper connections. All wiring diagrams can be referenced at the end of this brochure. SSH Controller (0 AMP) SSH-0- The SSH is a stand-alone single zone controller ideal for use with hot sprue bushings or machine nozzles.

4 Smart Series Temperature Control Systems TABLE OF CONTENTS PAGE Introduction - Typical System Configuration SSH Single Zone Controller - Single and Two-Zone Mainframes and Accessories 7-9 Single Zone High Power Mainframes 0 Smart Series Mainframes - Digital Current / Voltage Monitor Smart Series Accessories Standard Mainframe Connector Wiring Wiring Diagram for Hot Runner Molding System and Smart Series / G-Series Mold Connectors 7 Wiring Diagram for Hot Runner Molding System and High Power Smart Series / G-Series Mold Connectors Cables and Connector Kits 9- Mold Connector Pocket Layouts - Terminal Mounting Boxes - SSM Temperature Control Modules 7- DSS Temperature Control Modules 9-0 CSS Temperature Control Modules - TAS Temperature Alarm/Standby Heat Modules - CIM Microprocessor-Based Computer Interface Module Replacement Parts and Service Items - Input Power Wiring Diagrams 9-

5 Typical System Configurations SSM--0 DSS--0 CSS--0 Zones of Control ( AMP) MPC--C0-G PTC--TB-TS X MFP--G TC--C0-G MFS--G SSM--0 DSS--0 CSS--0 Zones of Control ( AMP) MPC--C0-G PTC--TB-TS MFP--G X TC--C0-G MFS--G SSM--0 DSS--0 CSS--0 Zones of Control ( AMP) MPC--C0-G PTC--TB-TS MFP--G X TC--C0-G MFS--G SSM-0-0 DSS-0-0 CSS-0-0 or Zones of High Power Control (0 AMP) MTC--G-IDC MPCH--C0-G X or X MFHP--G MFHP--G TC--C0-G PICH--G PTCH--TB-G MFS--G SSM-0-0 DSS-0-0 CSS-0-0 Zones of High Power Control (0 AMP) MTC--G-IDC MPCH--C0-G X MFHP--G TC--C0-G PICH--G PTCH--TB-G MFS--G

6 Smart Series Single Zone Temperature Controller Compact Easy-to-use Includes new, improved and unique features Provides microprocessorbased PID control More accurate than analog or variac controllers Built-in thermocouple diagnostics Ideal for use with a hot sprue bushing or a machine nozzle SSH-0-/ (0 AMP) Key Features Large Digital Display - For easier readability of temperature, % power and faults Setpoint Pushwheel - For setting desired setpoint temperature - Allows adjustment of setpoint before turning power on AUTO % Power Display - Shows % power output while in AUTO mode - Indicates average % power requirement on thermocouple failure - A diagnostic tool for solving problems Switchable Options Shorted Thermocouple Sensitivity Adjustment - Operation can be tailored to fast or slow reaction times - Sensitivity can be adjusted with internal switches - Very useful for zones with long startup times Switchable C/ F Operation - Scale indicated at startup K Type Thermocouple Support Operational Refinements Improved SmartStart - A more gradual temperature rise leads to a more effective heater dry out period, thereby extending heater life - SmartStart now available as an option in manual mode SelectiveCycle - A very high speed power output approach - Enables accurate temperature control and longer heater life Bumpless Transfer - When a thermocouple failure occurs, operation is automatically continued with a learned % power - Unique software accurately assigns percent power setting Third Fuse - Allows for display of low temperature alarm when the load fuses are blown Front Panel Digital LED Indicators BACKWARD THERMOCOUPLE SHORTED THERMOCOUPLE OPEN THERMOCOUPLE BUMPLESS TRANSFER FRONT PANEL LOCKOUT TEMP MODE FAHRENHEIT TEMP MODE CENTIGRADE PROCESS TEMP MANUAL % POWER LOCKOUT ERROR

7 Smart Series Single Zone Temperature Controller CONTROLLER SSH-0- SSH-0- VOLTS (VAC) 0 0 SSH-0-/ (0 AMP) Controller includes 9-foot power cord, mating mold power and thermocouple connector (CKPTM-) and two spare fuses (ABC-0). Additional cables and/or connectors must be ordered separately. See Page for detailed information on cables and connectors. Warranty: Three year (excluding triac and fuses). CABLE* MPTC-0 MPTC-0 LENGTH (FEET) 0 0 See page CKPTM- INCLUDED MOLD POWER AND THERMOCOUPLE CONNECTOR* CKPTIC- * S ORDERED SEPARATELY See page Front Panel Controls and Indicators. Process Temperature Display: Shows process temperature, thermocouple faults and other operational modes. Displays % power when switch () is pressed down.. Temperature Deviation Lights: Indicates deviation from setpoint. Outer lights blink at more than ±0 F ( C) from setpoint.. Auto / Manual / % Auto Power Switch: Selects AUTO or MANUAL control mode. Shows % power when pressed into % AUTO position.. LED Mode Indicators: Left LED illuminates during manual mode. Right LED illuminates when power is supplied to heater. Right LED blinks during SmartStart.. Setpoint Pushwheel: Three digit switch programs setpoint in AUTO mode. Right two digits program % power in MANUAL mode.. Power On/Off Switch: Controls AC power to module. Rear Panel. Mold Power and Thermocouple Output Connector: CKPTOC connects to the heater and thermocouple. Mating connector CKPTM- is supplied with controller.. Power Input Cord: Nineteen foot cord supplies power to controller. Plug supplied with SSH-0- (0 VAC) units. No plug supplied with SSH-0-.. Load Fuse Receptacles: Provides safe and easy replacement of load fuses.

8 7 A Smart Series Single and Two-Zone Mainframes (0 AMP Max.) B MFP-G MFP-G- A: AC0F (Power to Mainframe); ACF supplied with MFP-G- B: CKPTM- (Connector to heaters) This single-zone controller is ideal for use with Straight-Shot and Gate-Mate hot sprue bushings. Single and Two-Zone 0 AMP Mainframes The D-M-E Portable 0 AMP Mainframes are designed for use with 0 or AMP* Smart Series or G-Series Temperature Control Modules. Mainframe is supplied with power input and power-thermocouple output connectors. Circuit breaker provides safety for operation. Control modules and cables are to be ordered separately. NOTE: Maximum safe operating amperage is 0 AMPS per zone when using AMP modules. If application will draw more than 0 AMPS per zone, use AMP Mainframe (MFFPR-G). *User must install ABC0 (0 AMP) fuses in the AMP control modules to protect the mainframe. Single and Two-Zone 0 AMP Mainframes (0-0 Hz, single phase) ZONES S** MFP-G- MFP-G MFPR-G VOLTS WATTS PER ZONE CONNECTORS SUPPLIED () ACF (POWER IN) () CKPTM- (POWER-T/C OUT) () AC0F (POWER IN) () CKPTM- (POWER-T/C OUT) () AC0F (POWER IN) () CKPTM- (POWER-T/C OUT) **Includes frame and connectors listed. Modules and cables ordered separately. NOTE: Replacement power connectors in frame are also available on special order. Recommended Mold Pocket Layout (For Mold Power-Thermocouple Input Connector CKPTIC-) MFPR-G A B A: AC0F (Power to Mainframe) B: CKPTM- (Connector to heaters) Single zone, horizontal 0 amp controllers (SSH-0-/) also available. See page NO. -0 NC-B TAP.0 DEEP MIN. () PLACES 0. R REF.0 0. REF 0. R MOLD SURFACE MOUNTING SURFACE DIMENSIONS (all frames) 7"W x 9"H x 0"D (9"H dimension does not include connectors or handle).00 MIN.

9 Smart Series Single and Two-Zone Mainframe Accessories (0 AMP) For Use With MFP-G, MFP-G-, MFPR--G, SSH-0- and SSH-0- CKPTIC- Mold Power-Thermocouple Input Connector A Single-Zone Power-Thermocouple Input Connector is available for mounting in or on the mold to accept the power-thermocouple cable from the mainframe. Water resistant, the connector has an integral retaining latch for a secure cable connection and numbered screw-type terminals for power and thermocouple lead wires. * Can be mounted on top of mold for use with D-M-E Straight Shot hot sprue bushings. MPTC-0 MPTC-0 Armored Mold Power-Thermocouple Cables Single-Zone Mold Power-Thermocouple Cables are constructed of special lead wire for use in high temperature environments, and are available to connect the mainframe to the connector on the mold. Available in lengths of 0 or 0 feet. Integral retaining latches on the mainframe and mold connections provide secure cable connections. Connector configurations ensure proper insertion of cable. Replacement Connector Kits (for Controller and Cables) Power Input Connectors For Mainframe MALE POWER-T/C CONNECTORS; CKPTM- is on MPTC-0/0 Cables; Mates with Frame or CKPTF-L Only CKPTM-L Mates With CKPTF- Only FEMALE POWER T/C CONNECTORS; CKPTF- is on MPTC-0/0 Cables; Mates with Mold or CKPTM-L Only CKPTF-L Mates with CKPTM- Only ACF CKPTM- CKPTF- PTC--0 ACF AC0F VOLTS 0 0 CKPTM- CKPTM-L CKPTF- CKPTF-L PTC--0 AC0F CKPTM-L CKPTF-L Power-Thermocouple Output Connector (for Mainframe Bulkhead) CKPTOC- for CKPTIC- and CKPTM- or CKPTM-L Wiring Diagrams MALE FEMALE R W for CKPTOC- and CKPTF- or CKPTF-L W R

10 9 Smart Series Two-Zone Mainframe ( AMP) and Accessories AC0F MFFPR-G ACM MMJ FRAME DIMENSIONS: 7 W X 9 H X 0 D (9 H dimension does not include connectors or handle) Two-Zone AMP Mainframes Provides AMP (00 watts) per zone. For use with Smart Series or G-Series modules. Supplied with built-in cooling fan, power input, power output and thermocouple input connectors. Control modules and cables are ordered separately. TWO-ZONE AMP MAINFRAME (0 VAC, 0-0 Hz, SINGLE PHASE) MFFPR-G 00 Includes frame and connectors listed. Modules and cables ordered separately. NOTE: Replacement parts in frame are also available by special order. See pages and 7. AC0F* ACM* MMJ* PTC--TBG-TS WATTS PER ZONE * Included with MFFPR-G CONNECTORS SUPPLIED () AC0F (POWER IN) () ACM (POWER OUT) () MMJ (T / C IN) DESCRIPTION Female 0 VAC twist-lock power input connector (mates with male frame power input) Male 0 VAC power output connector (mates with female frame power outputs) Thermocouple mini-plug mates with frame as jack strip connector. zone, pre-wired terminal mounting box with terminal strip (mounts to mold; mates with PTC-00 or PTC-00 cables.) PTC00 PTC00 For use with MFFPR-G only Armored Mold Power- Thermocouple Cables ( AMP) Single-Zone Mold Power-Thermocouple Cable is constructed of special lead wire for use in high temperature environments. This cable connects the mainframe to the connector on the mold. Available in lengths of 0 or 0 feet. Retaining latches on the mold connector provide secure cable connections. W I R I N G MALE + - W R PTC--TBG-TS For use with MFFPR-G only Terminal Mounting Boxes - Prewired ( AMP) Terminal Mounting Boxes provide the easiest and most economical method of mounting power and thermocouple connectors on the mold. Constructed of plated heavy gauge steel, each box is precut and drilled for quick mounting of the box to the mold (-zone, prewired terminal mounting box with terminal strip shown with cover plate removed) NOTE: -pin connectors and pins are available as a special order only. These are crimp contacts. (See page Q- for mounting dimensions.) D I A G R A M S FEMALE - + W R

11 0 Smart Series Single Zone High Power Mainframes (0 AMP Max.) MFHP-G AC0F AC0M FRAME DIMENSIONS: 7 W x 9 H x 0 D (9 H dimension does not include connectors or handle) D MMJ E The D-M-E Portable Single-Zone High Power Mainframe is designed for use with 0 AMP Smart Series or G-Series temperature control modules. Mainframe is supplied with built-in cooling fan, power input, power output, and thermocouple input connectors. Circuit breaker provides safety for the operator. Control modules and cables are ordered separately. Single Zone 0 AMP Mainframes (0 VAC, 0-0 Hz, Single Phase) MFHP-G 700 MPCH-0 MPCH-0 AC0MI TC-0 TC-0 AC0F* AC0M* MMJ* PTCH-TBG TCS- WATTS (OUTPUT) Replacement Connectors and Accessories CONNECTORS SUPPLIED () AC0F (POWER IN) () AC0M (POWER OUT) () MMJ (T / C IN) DESCRIPTION 0 ft. mold power cable (0 VAC) ( AC0F twist-lock connector on mold end; AC0M twist-lock connector on frame end) 0 ft. mold power cable (0 VAC) (same connectors as MPCH-0) -Zone twist-lock mold power input connector (mounts in mold or terminal mounting box; accepts AC0F twist-lock connector on MPCH-0 or MPCH-0 cable) 0 ft. thermocouple cable ( MMJ mini-plug each end) 0 ft. thermocouple cable ( MMJ mini-plug each end) 0 VAC twist-lock power input connector (mates with frame power input) 0 VAC twist-lock power output connector (mates with frame power output) thermocouple mini-plug (mates with frame or jack strip connector) terminal mounting box (mounts to mold; accepts AC0MI and TCS-) jack strip connector *Included with MFHP-G mainframe TERMINAL MOUNTING BOX PTCH-TBG...0 REF..7 TERMINAL MOUNTING BOX PTCH-TBG (Connectors shown are ordered separately) D: TCS- E: AC0MI NOTE: Overall dimensions shown include allowances for hardware (assembly screws) but not connectors..0.0 /-0 TAP FOR SOCKET HEAD CAP SCREW (NOT SUPPLIED) TYPICAL ()

12 Smart Series Mainframes ( AMP) Thermocouple input with retaining latch Power output with retaining latch Cooling Fan WIDTH (W) Main AC power input strain relief 9 D-M-E Smart Series Mainframe ( AMP Max.) Configurations The configurations illustrated below provide a wide selection of zone capacities to suit most control applications. The, and zone frames (MFP,, and G) use individual frame sections. The thru zone frames use, or frame sections rigidly fastened together into one prewired integral unit which requires only one main AC power input connection. The Current Voltage monitor option will be factory installed when ordered at same time as Mainframe. Control modules, cables, mold connectors and other accessories are ordered separately (see table on page Q). MAINFRAMES ( Supplied with 0 AMP, -phase circuit breaker) MFPG MFPG MFPG STACK FRAMES ( Supplied with 70 AMP, -phase circuit breaker) MFPG MFP0G MFPG Each frame section (MFPG, MFPG, and MFPG) has its own cooling fan. Multi-section frame heights are multiples of 9 height shown (e.g. MFPG is 7 high). WORLDWIDE WIRING CAPABILITIES Unless otherwise specified, all Smart Series Mainframes will be supplied to accept 0 VAC, phase, -wire, 0-0 Hz input power. Wiring diagram (included on the access cover) illustrates the variety of other voltage, phase and load balancing arrangements possible, such as: (0-V, phase, -wire, 0-0 Hz), (0-0V, single phase, -wire, 0-0 Hz) and (0-0V, single phase, -wire, 0-0 Hz). These wiring adjustments can be performed in the field to suit the requirements of the application. If specified at the time of original order, D-M-E will supply the Mainframe required. S MFPG MFPG MFPG W * 0 * Dimension does not include connectors NOTE: Combination frames to accommodate both and 0 AMP modules (with or without communications) are available by special order. MFPG MFPG MFPG MFP0G MFPG MFPG MOLD POWER CABLE (0 OR 0 FOOT) THERMOCOUPLE CABLE (0 OR 0 FOOT) THERMOCOUPLE CONNECTOR TERMINAL MOUNTING BOX (OPTIONAL) MAINFRAME WITH CIRCUIT BREAKER DISCONNECT IS STANDARD. CURRENT VOLTAGE MONITOR IS OPTIONAL. Main AC input shown will always be in bottom frame section. For higher power requirements, individual power inputs and circuit breakers can be factory installed in each section of a stack frame on a special order basis. MOLD POWER INPUT CONNECTOR WITH ED POWER LEADS INSULATED CRIMP CONNECTORS (INCLUDED WITH MOLD POWER INPUT CONNECTOR)

13 Smart Series Mainframes ( AMP) Z O N E S 0 SMART SERIES MAINFRAMES Optional Current Voltage Monitor is Factory Installed in CV-Style Frames MFP TYPE FOR TEMPERATURE AND POWER CONTROL MFPG MFPG MFPG MFPG MFP0G MFPG MFPG MFP TYPE WITH CURRENT VOLTAGE MONITOR (CV-STYLE) MFPG-CV MFPG-CV MFPG-CV MFPG-CV MFP0G-CV MFPG-CV MFPG-CV MFCP TYPE FOR TEMP. CONTROL AND COMMUNICATIONS MFCPG MFCPG MFCPG MFCPG MFCP0G MFCPG MFCPG MFCP TYPE WITH CURRENT VOLTAGE MONITOR (CV-STYLE) MFCPG-CV MFCPG-CV MFCPG-CV MFCPG-CV MFCP0G-CV MFCPG-CV MFCPG-CV CABLES AND MOLD CONNECTORS REQUIRED (Not Included with Mainframes and Must Be Ordered Separately) MOLD POWER CABLES C0 = 0 FT. C0 = 0 FT. (SELECT LENGTH DESIRED) THERMOCOUPLE CABLES C0 = 0 FT. C0 = 0 FT. (SELECT LENGTH DESIRED) MOLD POWER INPUT CONNECTORS (INCL. CRIMP CONNECTORS) QTY. QTY. QTY. QTY. THERMOCOUPLE CONNECTORS MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC and and and and MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC and and and and MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MFPG MFPG-CV MFCPG MFCPG-CV MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC and and and and MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MFPG MFPG-CV MFCPG MFCPG-CV MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC 0 MFP0G MFP0G-CV MFCP0G MFCP0G-CV MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC and and and and MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MFPG MFP0G-CV MFCPG MFCPG-CV MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC and and and and MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC MFPG MFPG-CV MFCPG MFCPG-CV MPC-C0 or C0-G TC-C0 or C0-G PICG MTCG or MTCGIDC TERMINAL MOUNTING BOXES Z O N E S 0 ORDER S A and B or C (A) (B) (C) FOR POWER INPUT FOR THERMOCOUPLE CONNECTORS CONNECTORS QTY. CATALOG QTY. CATALOG QTY. PIC-TBG PIC-TBG COMBINATION POWER & TC CATALOG PIC-TBG MTC-TBG PTC-TBG PIC-TBG MTC-TBG PTC-TBG PIC-TBG MTC-TBG PTC-TBG PIC-TBG MTC-TBG PTC-TBG MTC-TBG PTC-TBG and and MTC-TBG PTC-TBG PIC-TBG MTC-TBG PTC-TBG MTC-TBG PTC-TBG and and MTC-TBG PTC-TBG Z O N E S 0 NOTE: For details on cables and connectors, see pages Q9- ORDER S A and B or C (A) (B) (C) FOR THERMOCOUPLE CONNECTORS FOR POWER INPUT CONNECTORS QTY. CATALOG CATALOG QTY. QTY. PIC-TBG PIC-TBG PIC-TBG PIC-TBG PIC-TBG MTC-TBG and MTC-TBG MTC-TBG MTC-TBG and MTC-TBG MTC-TBG and MTC-TBG MTC-TBG COMBINATION POWER & TC CATALOG PTC-TBG and PTC-TBG PTC-TBG PTC-TBG and PTC-TBG PTC-TBG and PTC-TBG PTC-TBG NOTES: Combination terminal mounting boxes are available with connectors prewired to terminal strips. See Q- for details. See page Q- for dimensional details. For below flush mounting of connectors, see mold pocket layouts on catalog pages Q-. See page Q- for current voltage monitor.

14 Smart Series High Power Mainframes (0 AMP) 0 AMP -phase circuit breaker 9" 9" MFHPG ( /" wide) 0 AMP -phase circuit breaker HIGH POWER MOLD POWER CABLE (0 OR 0 FOOT) THERMOCOUPLE CABLE (0 OR 0 FOOT) (USE ZONE CABLE) THERMOCOUPLE CONNECTOR TERMINAL MOUNTING BOX (OPTIONAL) MAINFRAME WITH CIRCUIT BREAKER DISCONNECT IS STANDARD; CURRENT VOLTAGE MONITOR IS OPTIONAL HIGH POWER MOLD POWER INPUT CONNECTOR INSULATED CRIMP CONNECTORS (INCLUDED WITH MOLD POWER INPUT CONNECTOR) 9" MFHPG (0 /" wide) 70 AMP -phase circuit breaker MFHPG ( /" wide) DIMENSIONS ABOVE DO NOT INCLUDE CONNECTORS all frames are " deep NOTE: Blank panels cover unused zones in frames (shaded panels above). For communications (MFCHP) type frames, these zones may be used for communications modules. The configurations illustrated at left provide, or zones of 0 AMP control for higher wattage heater applications. The Current Voltage monitor option will be factory installed when ordered at the same time as Mainframe. Control modules, cables, mold connectors and other accessories are ordered separately. Z O N E S Z O N E S SMART SERIES HIGH POWER MAINFRAMES OPTIONAL CURRENT VOLTAGE MONITOR IS FACTORY INSTALLED IN CV-STYLE FRAMES MFHP TYPE FOR TEMPERATURE CONTROL QTY. MFHPG MFHPG MFHPG (CV-STYLE) MFHPG-CV MFHPG-CV MFHPG-CV MFCHP TYPE FOR TEMP. CONTROL AND COMMUNICATIONS MFCHPG MFCHPG MFCHPG MFCHP TYPE WITH CURRENT VOLTAGE MONITOR (CV-STYLE) MFCHPG-CV MFCHPG-CV MFCHPG-CV CABLES AND MOLD CONNECTORS REQUIRED (NOT INCLUDED WITH MAINFRAMES) MOLD POWER CABLES C0 = 0 FT. C0 = 0 FT. (SELECT LENGTH DESIRED) QTY. QTY. QTY. MPCH-C0 or C0-G MPCH-C0 or C0-G MPCH-C0 or C0-G MFHP TYPE WITH CURRENT VOLTAGE MONITOR THERMOCOUPLE CABLES C0 = 0 FT. C0 = 0 FT. (SELECT LENGTH DESIRED) TC-C0 or C0-G TC-C0 or C0-G TC-C0 or C0-G NOTE: For details on cables and connectors, see pages Q9-. MOLD POWER INPUT CONNECTORS (INCL. CRIMP CONNECTORS) PICHG PICHG PICHG THERMOCOUPLE CONNECTORS MTCG MTCG MTCG TERMINAL MOUNTING BOXES NOTE: Combination frames to accommodate both and 0 AMP modules (with or without communications) are available by special order. Z O N E S QTY. ORDER S A and B or C (A) (B) (C) FOR THERMOCOUPLE CONNECTORS FOR POWER INPUT CONNECTORS QTY. QTY. COMBINATION POWER & TC PICH-TBG MTC-TBG PTCH-TBG PICH-TBG MTC-TBG PTCH-TBG PICH-TBG MTC-TBG PTCH-TBG NOTE: See page - for dimensional details. For below-flush mounting of connectors, see mold pocket layouts on pages -.

15 Smart Series Digital Current/Voltage Monitor Streamlined Design For Improved Performance The new Current/Voltage Monitor is simple to operate and features a large easy-to-read digital display. Ease of operation has been enhanced by streamlining the unit and eliminating unnecessary switches and controls. When setting the selector switch to the desired zone number, the AMPS function is selected. The meter will then display the amount of current being delivered by the selected module. Input voltage to the system can be measured by rotating the selector switch to one of the three line voltage positions. This will set the meter in the voltage function and display the voltage of the selected phase. Current Supply To Each Zone To monitor the current supply to each zone, simply set the rotary selector switch to the desired module zone number. The AMPS function is then automatically selected and is indicated by the letter A just to the right of the numbers in the display window. The meter displays the current being delivered to the heater load in amperes. Input Voltage From Each Phase Set the rotary selector to the desired phase voltage position. This automatically selects the volts function which is indicated when the letter V appears to the right of the numbers in the display window. The meter will display the line voltage of the selected phase.. CIRCUIT BREAKER/DISCONNECT Applies or removes power to all modules in the frame.. POWER ON LIGHT (amber) Illuminates when CIRCUIT BREAKER is in the ON position.. AMPS/VOLTS METER Digital multi-scale meter provides accurate readings of zone current (AMPS) or input voltage (VOLTS).. AMPS/VOLTS INDICATOR Appears automatically when either AMPS or VOLTS is selected.. SELECTOR SWITCH Multi-position switch automatically selects zone current or phase line voltage to be monitored. For systems with more than zones, additional meter and selector switch panels are supplied. Specifications Voltmeter Range Voltmeter Accuracy Maximum Voltmeter Input Input Voltage Ammeter Range Ammeter Accuracy Maximum Ammeter Input 90 to 90 VAC (for 0 volt systems) 90 to VAC (for 0 volt systems) ± % of reading, 0 to 0 Hz 00 VAC 0/0 VAC, 0 to 0 Hz 0 to ; 0 to 0; 0 to 0 Amperes ± 0 to 00% Duty Cycle, 0-0 Hz 0 Amperes NOTE: The Digital Current/Voltage Monitor is a factory installed option which replaces the standard circuit breaker/disconnect, and is supplied when CV-style mainframes are ordered. See pages and for appropriate mainframe catalog numbers.

16 Smart Series Accessories " SECTIONS SECTIONS SECTIONS SECTIONS Universal Floor Stand The Universal Floor Stand will accommodate all or 0 amp Mainframes from one to four sections high. Stand is made from heavy gauge steel and includes locking casters (00 lb. rating). All assembly and Mainframe mounting hardware is included. Heavy duty floor stand available for larger systems (000 lb. rating). RATING Floor stand width adjusts for - and - zone mainframes MFS--G 00 LBS /" MFS--G-HD* 000 LBS *HD stand not shown. Floor stand comes with plates for -zone frame mounting on -zone x pattern / Step-Down Transformer Kits (from 0 VAC to 0 VAC) Transformer Kits are pre-wired and include enclosed transformer (0 VAC input, 0 VAC output) with adjustable transformer voltage taps, one 0-foot cable for AC power-in (no connector), one -foot cable for mainframe (AC input), one safety switch, two extra fuses, floor stand (MFS--G) and all mounting brackets and hardware required. Shipped with instructions for easy assembly. Single section frames mount to front or rear of stand. POWER CAPACITY TK-A-G KVA TK9-A-G* 9 KVA TK-A-G * KVA TK0-A-G** 0 KVA Also Available:. Transformer only. Transformer and cables only. Transformers with other voltage or current capacities. Isolation Transformers Contact D-M-E for details and prices. Mainframe not included. Adapter plates for narrower frames available by special order. * Comes with plates for mounting zone on zone x pattern ** Supplied with MFS--G-HD for this transformer size or large and transformers mounted flat. NOTE: Power capacity needed depends on total load of system (i.e. number of zones and heater load per zone). Mainframe Blank Panels Used to cover unused zones in mainframes. Push-pull fasteners included in panel. MFBP0G covers one AMP zone; MFBP0G covers one 0 AMP zone (or two AMP zones). MFBP0G MFBP0G Module Replacement Fuses (sold in packages of ) AMPS ABC- ABC- ABC-0 0 X-0 0 X- Insulated Crimp Connectors For connection of mold power input connector leads to heater leads. (9 F / 90 C maximum temperature) AMPS WIRE GAUGE HWCC- (Bag of 0) HWCC- (Bag of 0) HWCC- (Bag of 0) RED - BLUE 0- YELLOW NOTE: Initial supply is provided with mold power input connectors.

17 Smart Series Mainframe Connector Wiring STANDARD MAINFRAME CONNECTOR WIRING ZONE THERMOCOUPLE INPUT Side of Mainframe THERMOCOUPLE INPUT CONNECTOR A B C ROW "C" ROW "B" ROW "A" ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS 7 (WHT) + (RED) ROW "B" TERMINALS (WHT) + (RED) ROW "B" TERMINALS (WHT) + (RED) ROW "B" TERMINALS (WHT) + 7 (RED) ROW "C" TERMINALS (WHT) + (RED) ROW "C" TERMINALS (WHT) + (RED) ROW "C" TERMINALS (WHT) + (RED) ROW "C" TERMINALS 7 (WHT) + (RED) ROW "A" TERM. 9 (WHT) ROW "C" TERM. 9 (RED) ROW "B" TERMINAL IS NOT USED ZONE POWER OUTPUT 9 B C A POWER OUTPUT CONNECTOR ROW "C" ROW "B" ROW "A" ROW "A" TERMINALS + ROW "A" TERMINALS + ROW "A" TERMINALS + ROW "A" TERMINALS 7 + ROW "B" TERMINALS + ROW "B" TERMINALS + ROW "B" TERMINALS + 7 ROW "C" TERMINALS + ROW "C" TERMINALS + ROW "C" TERMINALS + ROW "C" TERMINALS 7 + ROW "A" + "C" TERMINALS 9 ROW "B" TERMINAL IS NOT USED NOTE:. Mating cable connectors are wired the same as frame connectors shown.. Wires in frames are color coded for reference when rewiring of frame connectors is necessary (see owner's manual).. All grounds must be connected to ensure operator safety. HIGH POWER MAINFRAME CONNECTOR WIRING ZONE THERMOCOUPLE INPUT Side of Mainframe THERMOCOUPLE INPUT CONNECTOR A B C ROW "C" ROW "B" ROW "A" INSERT "A" INSERT "B" ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS (WHT) + (RED) ROW "A" TERMINALS 7 (WHT) + (RED) ROW "B" TERMINALS (WHT) + (RED) FOR ZONE CONNECTOR (SHOWN) POWER OUTPUT ZONE INSERT TERM INSERT "A" + INSERT "A" + INSERT "A" + INSERT "B" + INSERT "B" + + NO CONNECTION "B" FOR & ZONE CONNECTOR (WITH INSERT "A" ONLY) POWER OUTPUT POWER OUTPUT CONNECTOR ZONE INSERT TERM INSERT "A" + INSERT "A" + INSERT "A" +

18 7 Wiring Diagram For The D-M-E Hot Runner Molding System and Smart Series Mold Connectors HEATER POWER LEADS MANIFOLD HEATER ZONE MANIFOLD THERMOCOUPLE 7 9 C B A 7 9 ZONE WIRING CONNECTIONS ROW "A" TERMINALS + ROW "A" TERMINALS + ROW "A" TERMINALS + ROW "A" TERMINALS 7 + ROW "B" TERMINALS + ROW "B" TERMINALS + 7 ROW "B" TERMINALS + 7 ROW "C" TERMINALS + 9 ROW "C" TERMINALS + 0 ROW "C" TERMINALS + ROW "C" TERMINALS 7 + ROW "A" + "C" TERMINALS 9 ROW "B" TERMINAL IS NOT USED ROW "A" ROW "B" ROW "C" USE OHM METER TO MEASURE BETWEEN EACH HEATER POWER LEAD AND EACH THERMOCOUPLE LEAD. RESISTANCE SHOULD BE GREATER THAN 0,000 OHMS. MOLD THERMOCOUPLE CONNECTORS MTCG REAR VIEW THERMOCOUPLE LEADS WHITE (+) RED (-) MTCG PICG MTCG HEATER VOLTS MARKED ON HEATER HEATER VOLTS MARKED ON HEATER MOLD POWER INPUT CONNECTORS HEATER WATTS MARKED ON HEATER BEFORE POWER IS CONNECTED: USE OHM METER TO CHECK EACH HEATER POWER LEAD. RESISTANCE TO GROUND SHOULD BE GREATER THAN 0,000 OHMS. CHECK RESISTANCE* BETWEEN HEATER POWER LEADS. *MEASURED RESISTANCE OHMS ZONE ZONE ZONE ZONE TYPE "J" T/C ONLY BEFORE POWER IS CONNECTED: CHECK CONNECTIONS OF RED AND WHITE LEADS TO ENSURE PROPER CONNECTION TO THE CORRECT TERMINAL. USE OHM METER TO MEASURE BETWEEN RED & WHITE LEADS. RESISTANCE SHOULD BE LOW. ZONE WHT RED WHT RED WHT RED REAR VIEW ZONE 0 VOLTS X 0 VOLTS 0 WATTS 70 OHMS NOZZLE HEATER WITH INTEGRAL THERMOCOUPLE NOTES: All grounds must be connected to mold to ensure operator safety. All crimp connections can be eliminated by using terminal mounting box with terminal strip. See Q-

19 Wiring Diagram For The D-M-E Hot Runner Molding System and High Power Smart Series Mold Connectors HEATER POWER LEADS MANIFOLD HEATER ZONE ZONE ZONE 7 9 MTCG PICHG REAR VIEW 0 PICHG HIGH POWER MOLD POWER INPUT CONNECTORS MANIFOLD THERMOCOUPLE INSERT TERM ROW "A" + ROW "A" + ROW "A" + ROW "C" + ROW "C" + ZONE THERMOCOUPLE LEADS WHITE (+) RED (-) NO CONNECTION "B" + ZONE ZONE MOLD THERMOCOUPLE CONNECTOR REAR VIEW B A REAR VIEW BEFORE POWER IS CONNECTED: ZONE TERM USE OHM METER TO CHECK EACH HEATER POWER LEAD. RESISTANCE TO GROUND SHOULD BE GREATER THAN 0,000 OHMS CHECK RESISTANCE* BETWEEN HEATER POWER LEADS. BEFORE POWER IS CONNECTED: CHECK CONNECTIONS OF RED AND WHITE LEADS TO ENSURE PROPER CONNECTION TO THE CORRECT TERMINAL. HEATER VOLTS MARKED ON HEATER HEATER VOLTS MARKED ON HEATER HEATER WATTS MARKED ON HEATER 0 VOLTS X 0 VOLTS 0 WATTS 70 OHMS *MEASURED RESISTANCE OHMS NOTES: All grounds must be connected to mold to ensure operator safety. All crimp connections may be eliminated. Simply remove " leads from PIC connectors and wire directly. ZONE TYPE "J" T/C ONLY NOZZLE HEATER WITH INTEGRAL THERMOCOUPLE ZONE WHITE USE OHM METER TO MEASURE BETWEEN RED & WHITE LEADS. RESISTANCE SHOULD BE LOW. USE OHM METER TO MEASURE BETWEEN EACH HEATER POWER LEAD AND EACH THERMOCOUPLE LEAD. RESISTANCE SHOULD BE GREATER THAN 0,000 OHMS. RED 0 7 9

20 9 Smart Series /Mold Power and Thermocouple Cables MPC - -C0-G TO FRAME TO MOLD Mold Power Cables are used to connect the Mainframe to the Power Input Connector on the mold. Available in lengths of 0 or 0 feet. Integral retaining latches on both the frame and mold connectors provide secure cable connections. Connector configurations ensure proper insertion of cable. Cables are wired for, or zones ( AMP) and or zones (0 AMP) for use with the appropriate Smart Series Mainframes and Mold Power Input Connectors. Universal Mold Power Cable ( AMP) The MPC--C0 or 0-G Mold Power Cable also serves as a universal cable for connecting any AMP Smart Series Mainframe to any AMP Mold Power Input Connector. The maximum number of zones will be determined by the connector in the mold. Mold Power Cables ( AMP Max) 0 FOOT LONG 0 FOOT LONG OF FOR CONNECTIONS ZONES FROM AMP TO POWER INPUT (MAX.) FRAME (S) CONNECTOR MPC--C0-G MPC--C0-G,, ZONE PIC--G MPC--C0-G MPC--C0-G, ZONE PIC--G MPC--C0-G MPC--C0-G ZONE PIC--G SPECIAL CABLES Virtually any type of Conversion or Special Cable configuration can be provided by special order. Mold High Power Cables (0 AMP Max) 0 FOOT LONG 0 FOOT LONG FOR CONNECTIONS OF ZONES FROM 0 AMP TO POWER INPUT (MAX.) FRAME (S) CONNECTOR MPCH--C0-G MPCH--C0-G MPCH--C0-G MPCH--C0-G - ZONE ZONE PICH--G PICH--G TC - -C0-G TO FRAME TO MOLD Thermocouple Cables are used to connect the Mainframe to the Thermocouple Connector on the mold, and are available in lengths of 0 or 0 feet. Integral retaining latches on both the frame and mold connectors provide secure cable connections. Connector configurations ensure proper insertion of cable. Cables available are wired for, or zones for use with the appropriate Smart Series Mainframes and Thermocouple Connectors. Thermocouple Cables (for use with or 0 AMP Mainframes) These Thermocouple Cables serve as cables for connecting dissimilar Mainframes and Thermocouple Connectors. For example, the TC--C0-G could be used to connect a -zone frame to an -zone MTC--G connector. The maximum number of zones will be determined by the connector in the mold. Thermocouple Cables 0 FOOT LONG 0 FOOT LONG FOR CONNECTIONS OF ZONES FROM AMP TO THERMOCOUPLE (MAX.) FRAME (S) CONNECTOR TC--C0-G* TC--C0-G*,, ZONE MTC--G TC--C0-G TC--C0-G, ZONE MTC--G TC--C0-G TC--C0-G ZONE MTC--G * Used with all 0 AMP Mainframes.

21 0 Smart Series Mold Power Input Connectors For AMP Applications PIC--G Mold Power Input Connectors are mounted on the mold to accept power cable(s) from the Mainframe. They are supplied with six inches of numbered leads and a ground wire. All three AMP connectors are the same physical size and use -gauge wire. Only the number of active pins change. The 0 AMP connectors are supplied with 0-gauge leads and are attached to screw terminals. Each is equipped with an integral retaining latch to provide a secure cable connection. Connector configuration ensures proper insertion of cable. Splicing of leads to heater power leads is easily accomplished with the Insulated Crimp Connectors supplied. MOLD POWER INPUT CONNECTORS (PIC--G, PIC--G, PIC--G).9 NOTE: Ground wire must be connected to mold to ensure operator safety. PIC--G PIC--G For 0 AMP Applications.70.. DIA. ( HOLES)... NOTE: Dimensions shown may vary slightly..7 RADIUS MOUNTING SURFACE Mold Power Input Connectors PIC--G PIC--G PIC--G PICH--G PICH--G OF ZONES (MAX.) NOTE: Replacement parts and extraction tools can be found on page 7 AMPS (MAX.) PER ZONE 0 0 PICH--G MOLD POWER INPUT CONNECTORS (PIC--G). Insulated Crimp Connectors AMPS FOR WIRE GAUGE HWCC- 0 PCS HWCC- 0 PCS. - PICH--G NOTES: Connector PICH--G is dimensionally identical to thermocouple connector MTC--G. See page.. DIAMETER HOLES...7 RADIUS HWCC- 0 PCS NOTE: Initial supply is provided with mold power input connectors. Also, see page For: PICH--G and PICH--G, direct wiring without crimp connectors is possible by removing " leads..0.0 MOUNTING SURFACE

22 Quick Connection System New Product Stripping Special Tools ols 0, and Position Insulation Displacement Connectors (IDC) MTC--G-IDC MTC--G-IDC MTC--G-IDC These connectors are plug compatible with D-M-E standard MTCG, MTCG, and MTCG thermocouple connectors, and offer several advantages. No stripping of wire necessary No special tools required No screw terminals to tighten and no forgetting if wire is secured Saves time and reduces labor costs Cut wire to length, insert wire in the opening, push in tab, and the wire is terminated Easy wiring of thermocouples for new installation Easy repair of existing molds Can accept wires 0 - AWG* Leverage screwdriver tip to force out orange actuator Insert wire into hole as shown and push actuator with thumb Do Not Strip Wire! Use only 0 - AWG wire Connector Supplied with Latched Base MTC--G-IDC MTC--G-IDC MTC--G-IDC DIMENSION OF PINS M H Wire is terminated when orange actuator tab is pushed in flush *Not suitable for wires larger than AWG wire; stranded wire is preferred.

23 Smart Series Mold Thermocouple Connectors MTC--G Thermocouple Connectors are mounted on the mold to use with thermocouple cable(s) from the Mainframe. Screw type terminals for use with iron(+) and constantan(-) thermocouple leads are numbered and coded on the side and bottom of each connector. All three connectors are equipped with integral retaining latches to provide a secure cable connection. Connector configuration ensures proper insertion of cable. Pins are made of copper alloy and are silver plated. Experience has proven that iron and constantan are not required. MTC--G MTC--G MTC--G MTC--G TPC-000 DIMENSION OF PINS M H NOTE: MOLD POWER INPUT CONNECTOR PICH--G IS DIMENSIONALLY IDENTICAL TO MTC--G MTC--G MOLD THERMOCOUPLE CONNECTOR MTC--G MTC--G-IDC MTC--G MTC--G-IDC MTC--G MTC--G-IDC MOLD POWER AND THERMOCOUPLE CONNECTOR TPC H M H M TPC-000 Thermocouple / Mold Power Connectors.77 DIAMETER HOLES.9.0 RADIUS (MIN.).. RADIUS (MIN.) OF ZONES (MAX.) MTC--G* MTC--G MTC--G..97 MOUNTING SURFACE..97. MOUNTING SURFACE TPC-000 NOTE: DIMENSIONS SHOWN ARE FOR THE MTC-G, MTC-G AND MTC-G CONNECTORS * Use with, and zone, 0 AMP mainframes

24 Mold Connector Pocket Layouts NOTE: Drawing depicts below-flush mounting. Disregard dimensions marked with * for surface mounting. NOTE: Fasten ground wire (GREEN) to a convenient place in pocket Where space or mold handling and storage requirements do not permit the use of Terminal Mounting Boxes, the connectors can be below-flush or surface mounted. See drawings below and page Q- for dimensions. Below-Flush and Surface Mounting of Mold Power Input Connectors ( AMP).00*.*.9 NO. -0 NC-B TAP () PLACES MOLD SURFACE Typical for: PIC--G PIC--G PIC--G.0 RADIUS TYPICAL.0*.0* MOUNTING SURFACE..00.*.00 MINIMUM.0 RADIUS TYPICAL.00 NOTE: Disregard dimensions marked with* for surface mounting. Below-Flush and Surface Mounting of Thermocouple Connectors MOLD SURFACE.*.00*.* MOUNTING SURFACE.0.00 MINIMUM D.0 RADIUS TYPICAL M C C L Y DIMENSION M C D Y.0 RADIUS TYPICAL MTC--G MTC--G MTC--G NO. - NC-B () PLACES NOTE: Mold power input connector PICH--G is dimensionally identical to MTC--G.

25 Mold Connector Pocket Layouts (cont.) Below-Flush and Surface Mounting of Mold Power Input Connectors (0 AMP) 7.*..0 RADIUS TYPICAL..0.00*.0 RADIUS TYPICAL. NO. - NC-B TAP () PLACES For PICH--G NOTE: Drawing depicts below-flush mounting. Disregard dimensions marked with * for surface mounting. MOLD SURFACE.00* MOUNTING SURFACE.00 MINIMUM For PICH--G (Use pocket dimensions shown on pages - as detailed for thermocouple connector MTC--G.)

26 Smart Series Terminal Mounting Boxes Pre-wired Combination Terminal Mounting Boxes Includes terminal strip for ease of wiring, all necessary connectors installed, and power connector pre-wired to a terminal strip. All units shown without covers. PTC--TB-TS PTC--TB-G-TS PTC--TB-G-TS PTC--TB-TS PTC--TB-GTS is not to be used with SSH-0-, SSH-0-, MFP--G, MFP--G-, MFP--G, MFPR--G controls & mainframes For use with PTC-00 or PTC-00 Cables only. See page. PTC--TB-G-TS PTC--TB-G-TS PTC--TB-TS Combination Terminal Mounting Boxes - with Terminal Strip X Y H M M ACCEPTS PTC--TB-G-TS* See page 9 PTC--TB-G-TS** PIC--G, MTC--G** PTC--TB-G-TS** PIC--G, MTC--G** PTC--TB-G-TS** PIC--G, MTC--G** PTC--TB-TS** PIC--G, MTC--G** PTC--TB-TS** PIC--G, MTC--G** PTC--TB-TS** PIC--G, MTC--G** **Comes with all necessary connectors installed and power connector pre-wired to a terminal strip. *Power & thermocouple connectors are pre-wired.

27 Smart Series Terminal Mounting Boxes Terminal Mounting Boxes for Mold Power Input Connectors X Y H M M ACCEPTS PIC--TB-G PICH--TB-G PICH--TB-G PIC-, or -G PICH--G PICH--G Terminal Mounting Boxes for Thermocouple Connectors X Y H M M ACCEPTS PTC--TB-G (Connectors ordered separately) MTC--TB-G MTC--TB-G MTC--TB-G Combination Terminal Mounting Boxes MTC--G MTC--G MTC--G X Y H M M ACCEPTS PTC--0 PTC--TB-G () CKPTIC- PIC--G, MTC--G PTC--TB-G PIC--G, MTC--G PTC--TB-G PIC--G,MTC--G PTC--TB-G PTCH--TB-G** PTCH--TB-G PTCH--TB-G PTC AC0MI, TCS- PICH--G, MTC--G PICH--G, MTC--G TPC-000 *Used with -zone, AMP mainframe MFFPR-G ** Used with -zone, 0 AMP mainframe MFHP-G Terminal Mounting Boxes PTC-00 X Y PTC--TB-G H PTC--0 Terminal Mounting Boxes provide the easiest and most economical method of mounting power and thermocouple connectors on the mold. Constructed of plated heavy gauge steel, each box is precut and drilled for quick mounting of the connector to the box, and box to the mold. Connector mounting hardware is supplied. Connectors are ordered separately. M NOTE: Overall dimensions shown include allowances for hardware (assembly screws) but not connectors. M -0 TAP FOR SOCKET HEAD CAP SCREW (NOT SUPPLIED) TYPICAL () PLACES

28 7 Smart Series Microprocessor-Based Temperature Control Modules with Digital Display and Setpoint Pushwheel COMPATIBLE WITH TAS-0- ALARM AND SYSTEM CONTROL FUNCTIONS. SEE PAGES -. SSM--0/0 ( AMP) & SSM-0-0 (0 AMP) The SSM--0 is the second generation of the popular SSM-G. This version maintains simplicity of operation with simultaneous display of setpoint and temperature. Other new, improved, and unique features include: Key Features Large Digital Display - For easier readability of temperature, % power and faults Setpoint Pushwheel - For setting desired setpoint temperature - Allows adjustment of setpoint before turning power on Auto % Power Display - Shows % power output while in AUTO mode - Indicates average % power requirement on thermocouple failure - Serves as a diagnostic tool for solving hot runner system problems Operational Refinements Improved SmartStart - A more gradual temperature rise leads to a more effective heater dry-out period, thereby extending heater life - SmartStart now available in MANUAL mode (optional) SelectiveCycle - A very high speed power output approach - Enables accurate temperature control and longer heater life Bumpless Transfer - When a thermocouple failure occurs, operation is automatically continued with a learned % power - Unique software accurately assigns percent power setting Third Fuse - Allows for alarm output when the load fuses are blown - Protects module from application of excessive voltage Anti-Arcing Feature - Protects circuit board from damage when module is either inserted or removed under power NOTE: SSM-0-0 is twice as wide as above and has circuit breaker instead of power on/off switch. Switchable Options Boost, Idle and Power Off Features - Provides system-wide adjustment of temperatures - Enables alarm audio/visual output and remote alarms - Requires TAS-0- module and communications mainframe (See pages Q- for more information on these capabilities) Unique AutoBoost Option - Instantaneously opens frozen gates on startup - TAS module or mainframe communications are not required Lights Out Feature - After stabilizing at setpoint, display turns off; when a fault occurs, display is turned on and flashes - For easier detection of faults Shorted Thermocouple Sensitivity Adjustment - Operation can be tailored to fast or slow reaction times - Sensitivity can be adjusted with internal switches - Very useful for manifold zones with long startup times Switchable C/ F Operation - Scale indicated at startup K Type Thermocouple Support

29 Smart Series Microprocessor-Based Temperature Control Modules with Digital Display and Setpoint Pushwheel SSM--0/0 ( AMP) & SSM-0-0 (0 AMP) Warranty: Three years (excluding triac and fuses) Fuse Requirements ( AMP only) () ABC- fuses (Bussman only) () spare fuses included with module MODULE SSM--0 SSM--0 SSM-0-0 VOLTAGE (VAC) AMPS 0 WATTS Note: Standard (0 VAC) modules are compatible with mainframes wired for either 0 VAC three phase (standard) or 0 VAC single phase. Front Panel Controls and Indicators. Process Temperature Display Indicates process temperature, thermocouple faults and other operational modes. Displays % power when switch () is in % Auto position.. Temperature Deviation Lights Indicates deviation from setpoint. Outer lights blink when temperature is more than ±0 F ( C) from setpoint.. Auto/Manual/Auto % Power Switch Selects AUTO or MANUAL control mode. Shows % power when pressed into % AUTO position.. LED Mode Indicators Left LED illuminates during MANUAL mode. Right LED illuminates when power is supplied to heater. Right LED blinks on and off during SmartStart.. Setpoint Pushwheel Three-digit switch programs setpoint in AUTO mode. Right two digits program % power in MANUAL mode.. Power On/Off Switch Controls AC power to module. Front Panel Digital LED Indicators BACKWARD THERMOCOUPLE SHORTED THERMOCOUPLE OPEN THERMOCOUPLE BUMPLESS TRANSFER POWER OFF STANDBY HEAT BOOST TEMP MODE FAHRENHEIT TEMP MODE CENTIGRADE PROCESS TEMP MANUAL % POWER FRONT PANEL LOCKOUT LOCKOUT ERROR

30 9 Smart Series Microprocessor-Based Temperature Control Modules with Dual Digital Display COMPATIBLE WITH TAS MODULE ALARM AND STANDBY HEAT FUNCTIONS. SEE PAGES Q- DSS--0/0 ( AMP) & DSS-0-0 (0 AMP) The DSS- Smart Series Module has dual digital displays providing readouts of both process and setpoint temperatures at a glance. Closed-loop, fuzzy logic PID control, and auto-tuning of PID parameters provide precise control even under the most adverse processing conditions. In the event of a thermocouple failure, the DSS can automatically invoke bumpless transfer to a percent power mode based on the last valid percentage learned before the thermocouple failure. If desired, manual bumpless transfer may be selected, in which case a thermocouple fault will turn off power to the heater until the manual percent power mode is activated by the operator. A unique feature of the DSS is a 00% power option. For a switch-selectable, interval of or 0 seconds, full power can be immediately delivered to the heater to rapidly break through frozen gates to achieve quicker start-ups. The 00% power mode can be disengaged at any time by simply pressing any front panel button. NOTE: DSS-0-0 is twice as wide as above; has circuit breaker instead of F/F lights and power on/off switch. Indicator lights provide quick reference for module control modes, temperature deviation and blown fuses. The process temperature display also provides quick diagnostics of thermocouple faults, using the following abbreviated codes: Shi = Shorted Thermocouple opi = Open Thermocouple bci = Reversed Thermocouple The DSS module also includes a Smart Start mode to safely bake out damaging internal heater moisture at system start-up and to prolong heater life. Fast or slow load modes may also be selected to protect smaller heaters or compensate for slow loads such as externally heated manifolds. An accurate, durable and full-featured module, the DSS is fully compatible with all Smart Series or G-Series AMP mainframes. Front Panel Controls and Indicators. SMART START LIGHT Indicates Smart Start is on.. PROCESS TEMPERATURE DISPLAY Indicates process temperature and thermocouple faults as described above.. TEMPERATURE DEVIATION LIGHTS Indicates deviation from setpoint. Outer lights blink at more than ±0 F from setpoint.. SETPOINT DISPLAY Indicates setpoint temperature or percent power, depending on controller mode.. AUTO/MANUAL SWITCH Selects auto or manual control mode.. AUTO LIGHT Indicates auto mode. 7. MANUAL LIGHT Indicates manual mode.. 00% POWER SWITCH Indicates 00% power output for selectable interval of or 0 seconds % POWER LIGHT Indicates 00% power mode. 0. UP ARROW Increases desired setpoint value.. DOWN ARROW Decreases desired setpoint value.. F/F LIGHTS Illuminate when fuse is blown.. POWER ON/OFF SWITCH Front Panel Digital LED Indicators BACKWARD THERMOCOUPLE SHORTED THERMOCOUPLE OPEN THERMOCOUPLE

31 Smart Series Microprocessor-Based Temperature Control Modules with Dual Digital Display 0 DSS--0/0 ( AMP) & DSS-0-0 (0 AMP) Performance Specifications Auto and Manual Control Modes: Time proportioning/selective Cycle Temperature Range: Ambient to 999 F (7 C) Control Accuracy: ± F (0. C) dependent on the total thermal system Temperature Stability: ± 0.% of full scale over the ambient range of to 0 F (0 to 0 C) Calibration Accuracy: Better than 0.% of full scale Power Response Time: 0. seconds. Manual Control: Adjustable from 0-00%, maintains output power to within % of set point. Smart Start : Linear voltage ramping. Maximum Smart Start Duration: minutes Smart Start Override Temperature: F ( C) 00% Power: Applies 00% power to the output. Jumper selectable inhibit or S =, L = 0 seconds. Operational Mode Priority: Smart Start precedes auto mode. Thermocouple (T/C) break, reversed or shortened T/C overrides Smart Start and auto modes. Manual control overrides auto mode, T/C breaks, reversed or shortened thermocouples. Output is inhibited during all fault conditions Input Specifications Thermocouple Sensor: External T/C Residence: T/C Isolation: Cold Junction Compensation: T/C Break, Reversed & Shorted Protection: Input Impedance: Input Amplifier Stability: Common Mode Rejection Ratio: Power Supply Rejection: Output Specifications Voltage Power Capability: Output Drive: Overload Protection: Transient Protection: Power Line Isolation: Type J, grounded or ungrounded. Less than 0. F/Ω.. Isolated by control circuit power supply Automatic, better than 0.0 F/F (0.0 C/ C). Automatically inhibits power to heater unless bumpless transfer is invoked.. Megohms Greater than 0.0 F/ F (0.0 C/ C). Greater than 0dB. Greater than 0dB. AMP: 0 nominal, single phase, 0 VAC available, amperes, 00 0 VAC (00 0 VAC). 0 AMP: 0 amperes, VAC Internal solid state triac, triggered by zero AC crossing pulses. AMP: Fuses are provided on both sides of AC line. 0 AMP: Fast acting circuit breaker. dv/dt and transient pulse suppression included. Optically and transformer isolated from AC lines. Isolation voltage is greater than 00 volts. Controls and Indicators Auto/Manual Selection: Push-button switch with LED indicators adjacent to switch. Setpoint Adjustment: Push-button up & down arrow keys. 00% Power Selection: Push-button switch with LED indicator adjacent. Power On/Off: AMP rocker switch ( AMP) or 0 AMP circuit breaker (0 amp). Both are UL, CSA, VDE approved. Setpoint Display: Three 0., seven segment digit display. Process Display: Three 0., seven segment digit display. Also displays alarm codes and flashing 00 for 00 power operation. 00% Power Indication: Red LED adjacent to 00% power key flashes. Process display flashes 00. Auto Indication: Illuminates green LED adjacent to Auto/Man key. Manual Indication: Illuminates yellow LED adjacent to Auto/Man key. Smart Start Indication: Illuminates green LED above the process display. Shorted T/C Indication: Flashes Shi in process display. Opened T/C Indication: Flashes opi in process display. Reversed T/C Indication: Flashes bci in process display. Temperature Deviation Indicators: Five separate LEDs: ±0 F/ C = Red ±0 F/ C = Yellow 0 = Green. Blown Fuse Indicators: neon indicators ( AMP only) Electrical Power Specifications Input Voltage: 0/0 VAC + 0% -% Frequency: 0/0 Hz DC Power Supplies: Internally generated, regulated and compensated Module Power Usage: Less than watts, excluding load. Dimensions: AMP: W x 7 H x 7 / D (.0 x 7.7 x 9.0 cm) 0 AMP: W x 7 H x 7 / D (0.0 x 7.7 x 9.0 cm) NOTE: Standard (0 VAC) modules are compatible with mainframes wired for either 0 VAC three phase (standard) or 0 VAC single phase. FOR C OPERATION: Switch to C on front panel. FUSE REQUIREMENTS ( AMP ONLY): () ABC- Fuses (Bussman only) NOTE: () spare fuses included with module. WARRANTY: Three years (excluding triac and fuses) Smart Series Microprocessor-Based Temperature Control Modules (0 VAC, standard) DSS--0 DSS-0-0 AMPS 0 WATTS (0 VAC, optional) DSS--0 AMPS WATTS 00

32 Smart Series /Microprocessor-Based Temperature Control Modules with Digital Display and Communications COMPATIBLE WITH TAS MODULE ALARM AND STANDBY HEAT FUNCTIONS. SEE PAGES Q- CSS--0/0 ( AMP) & CSS-0-0 (0 AMP) The CSS- Communications Smart Series Module provides the molder with the first fully comprehensive temperature control module. This microprocessor-based unit incorporates the most complete list of control features while providing full SPI protocol communications capability with a D-M-E CIM (Computer Interface) Module (see page Q-). While the CSS module was designed with computer integrated manufacturing in mind, it also provides the highest level of performance as a stand-alone module. When operating independently the CSS offers these features: A multi-function display, advanced diagnostics, interactive Smart Start and auto or manual bumpless transfer. A setpoint memory feature also allows the user to power up the module with the same setpoint as the day before. It is compatible with all Smart Series or G-Series amp main frames. The advanced diagnostics will automatically alert the user to unusual fault conditions. This is done by multiplexing the flowing fault codes with the normal display in three second intervals: Shi = Shorted Thermocouple opo = Open Triac bci = Reversed Thermocouple ShO = Shorted Triac opi = Open Thermocouple GFI = Ground Fault Over and under temperature warnings are indicated by flashing LED s directly under the display. With its unique Smart Start* function, the CSS has the ability to dry out a heater which may have acquired moisture inside its case. Smart Start automatically applies low voltage to the heater after initial start-up. With this low voltage applied, the module analyzes the heater s conditions. If a ground leakage is sensed, the module will go into a bake-out procedure which drives moisture from the heater. In the event of a thermocouple failure, the CSS can automatically invoke bumpless transfer to a percent power mode based on the last valid percentage learned before the thermocouple failure. If desired, manual bumpless transfer may be selected in which case a thermocouple fault will turn off power to the heater until the manual percent power mode is activated by the operator. *U.S. Patent No.,09, Front Panel Digital LED Indicators BACKWARD THERMOCOUPLE OPEN TRIAC SHORTED THERMOCOUPLE SHORTED TRIAC OPEN THERMOCOUPLE GROUND FALT Front Panel Controls and Indicators. DIGITAL LED DISPLAY: Indicates setpoint temp, percent power, process temp, load current, and fault conditions.. TEMPERATURE DEVIATION INDICATORS: Shows deviation from setpoint. Outer lights blink at more than ±0 F. from setpoint.. SMART START LIGHT: Indicates Smart Start is on.. SPI PROTOCOL LIGHT: Indicates control is from a remote host system.. UP ARROW KEY: Increases the desired setpoint value.. DOWN ARROW KEY: Decreases the desired setpoint value. 7. SELECT/ENTER KEY: Selects either Setpoint (temperature/percent power), Amps (load current), or Process Temperature.. SETPOINT LIGHT: Indicates Setpoint is on display. Setpoint changed but not entered if flashing. 9. AMPS LIGHT: Indicates load current is on display. 0. TEMP LIGHT: Indicates process temperature is on display.. SIDE ARROW KEY: Auto/manual select.. AUTO LIGHT: Auto mode selected.. MANUAL LIGHT: Manual mode selected.. F/F LIGHTS: Illuminate when fuse has blown.. POWER ON/OFF SWITCH. F/ C INDICATOR: Illuminates when C mode is selected.

33 Smart Series /Microprocessor-Based Temperature Control Modules with Digital Display and Communications Output Specifications Voltage Power Capability: AMP: 0 nominal, single phase, 0 VAC available, Amperes, 00 0 VAC (00 0 VAC). 0 AMP: 0 Amperes, VAC Output Drive: Internal solid state traic, triggered by zero AC crossing pulses. Overload Protection: AMP: Fuses are provided on both sides of AC line 0 AMP: Fast acting circuit breaker. Transient Protection: dv/dt and transient pulse suppression included. Power Line Isolation: Optically and transformer isolated from AC lines. Isolation voltage is greater than 00 volts. Controls and Indicators Setpoint Control: Two buttons up and down, one button used to enter setpoint. Range: 0 to 999 F (0 to 7 C) Resolution: F ( C) Auto/Manual Selection: Push button switch toggles mode. LED indicates mode of operation. Power On-Off: Process Temp Selection: One push button with one LED indicator. Selected by select/enter push button. Load Current Selection: One push button with one LED indicator. Selected by select/enter push button. Multi-Function Display: Smart Start Indicator: LED above display window illuminates. F/ C Indicator: LED illuminates indicating C mode. Blown Fuse Indicators: neon indicators ( amp only) Shorted Thermocouple (T/C): (Shi) alternates with normal display. Shorted Output (Triac): (ShO) alternates with normal display. Open T/C: (opi) alternates with normal display. Open Output (Triac): (opo) alternates with normal display. Reversed T/C: (bci) alternates with normal display. Ground Fault: (GFI) alternates with normal display. SPI Protocol Indicators: LED above display window illuminates. Temperature Deviation Indicators: Separate LEDs: ±0 F/ C = (Blinking Red), ±0 F/ C = (Yellow), Electrical Power Specifications Input Voltage: 0F / 0C =Green) 0/0 VAC + 0% -0% Frequency: 0/0 Hz DC Power Supplies: Internally generated, regulated and compensated Module Power Usage: Less than watts, excluding load Dimensions: AMP: W x 7 H x 7 D (.0 x 7.7 x 9.0 cm) 0 AMP: W x 7 H x 7 D (0.0 x 7.7 x 9.0 cm) Performance Specifications Auto and Manual Control Modes: Time proportioning/selective Cycle Temperature Range: Ambient to 999 F (7 C) Control Accuracy: ±0.%(0.C) dependent on the total thermal system Temperature Stability: ±0.% of full scale over the ambient range of to 0 F (0 to 0 C) Calibration Accuracy: Better than 0.% of full scale Cycle Time: 0.0 seconds at 0Hz, 0.00 at 0 Hz Power Response Time: 0.00 seconds at 0 Hz, 0.00 at 0 Hz Reset Automatic: Corrects reset to no more than ± F( C) at all settings Manual Control: Advanced Diagnostics Indicators: EDS and -digit, 7-segment display Smart Start (SS): SS Duration: SS Override Temperature: Operational Mode Priority: Input Specifications Thermocouple (T/C) Sensor: External T/C Resistance: T/C Isolation: Cold Junction Compensation: T/C Break, Reversed & Shorted Protection: Input Type: Input Impedance: Input Protection: Input Amplifler Stability: Input Dynamic Range: Common Mode Rejection Ratio: Power Supply Rejection Ratio: Communication Inputs: CSS--0/0 ( AMP) & CSS-0-0 (0 AMP) Manual (% Power) Control: Two buttons up and down, one button used to Enter setpoint Range: 0 to 99% amp rocker switch ( amp) or 0 amp circuit breaker (0 amp). Both are UL, CSA, VDE approved. () 7-segment LED, 0. inch digital displays with decimal point used in load current display. Alarm characters also display. Adjustable from 0-99%. Maintains output power to within % of setting using the selective cycle power drive. Variable voltage steps from 0 to 0 volts repeatable over a 9-minute period. The module will escape from this mode if leakage falls below 0mA limit.. If dry out is not required then a fast pass check of voltage is implemented over 0 seconds. 0 seconds to 9 / minutes 00 F (9 C) Ground fault overrides all modes SS precedes auto mode SMART SERIES MICROPROCESSOR- Shorted output overrides SS and Auto mode Thermocouple (T/C) break overrides SS and Auto modes BASED TEMPERATURE CONTROL Open output overrides SS and Auto mode MODULES Manual control overrides T/C break, reversed T/C and auto modes The output is inhibited during all fault conditions Remote control overrides local control (0 VAC, standard) Type J grounded or ungrounded High impedance potentiometric input allows long distance T/C wiring Isolated by control circuit power supply Automatic, better than 0.0 F/F (0.0 C/C ) Automatically inhibits power to heater, unless automatic bumpless transfer is invoked Potentiometric Megohms Diode clamp, RC filter Greater than 0.0 F/F (0.0 C/ C) 00 F ( C) Greater than 00dB Greater than 90 db Data alliance is optically coupled at 00 volts isolation NOTE: Standard (0 VAC) modules are compatible with main frames wired for either 0 VAC three phase (standard) or 0 VAC single phase. FOR C OPERATION: Switch to C on circuit board. FUSE REQUIREMENTS ( AMP ONLY): () ABC- Fuses (Bussman only) NOTE: () spare fuses included with module. WARRANTY: Three years (excluding triac and fuses) CSS--0 CSS-0-0 AMPS WATTS (0 VAC, optional) AMPS WATTS CSS--0 00

34 Smart Series Temperature Alarm/System Control Modules TAS-0-/ Temperature Alarm Function Provides alarm for over or under temperature, or diagnostic error Provides visual and audible indications of an alarm The audible alarm () can be turned on or off with switch () Relay contacts () are provided to allow hook-up of remote equipment such as a light, a conveyor or a machine function Relay contacts are unaffected by the position switch () An infinite number of zones of control can be monitored as long as they are contained within the same communications-style mainframe as the TAS module System Control Functions Up to zones can be controlled remotely at one time. These zones must be contained within the same communications-style mainframe as the TAS module. NORMAL / IDLE Rotary switch () provides remote control of DSS--0/0, CSS--0/0 and the new SSM--0/0 Control modules can all be commanded to respond from NORMAL to IDLE (Standby Heat) In IDLE, the modules will adjust to a setting of 9 C (00 F) Exception: SSM--0/0 adjusts to a setting of 00 C ( F) Moving the rotary switch back to NORMAL restores all modules to their established setpoints The user can select IDLE for temporary lowering of all zones to prevent material degradation This feature can be used to keep heaters warm enough to prevent absorption of moisture BOOST / OFF The new SSM--0/0 can be placed into BOOST and OFF BOOST will raise the setpoint of the module by 0, 0, or 0% OFF shuts off power to the heater but allows the user to monitor cool down of the hot runner system Each SSM--0/0 can be individually programmed to respond to OFF, IDLE and BOOST commands The user can quickly drive all nozzle zones into BOOST to open frozen gates Front Panel Controls and Indicators. POWER ON INDICATOR: LED illuminates when power is applied to the module.. AUDIBLE ALARM: Emits a loud audible alarm when the alarm switch () is placed in the position (ON) and an alarm condition is sent by a compatible control module.. ALARM INDICATOR: LED illuminates when an alarm condition is sent by a compatible module.. AUDIO ALARM ON/OFF SWITCH: Turns the audio alarm () on or off.. ALARM RELAY CONNECTOR: Provides relay contacts for use with remote equipment. Mating connector is supplied.. SYSTEM CONTROL SWITCH: Activates the OFF, IDLE and BOOST mode in all compatible modules. 7. POWER ON/OFF SWITCH: Controls AC power to the module.

35 Smart Series Temperature Alarm/System Control Modules TAS-0- TAS-0- VOLTS 0 VAC 0 VAC NOTE: Standard (0 VAC) modules are compatible with mainframes wired for either 0 VAC threephase (standard) or 0 VAC single-phase. Use TAS-0- for 0 VAC operation. FUSE REQUIREMENTS: () ABC- fuses. NOTE: () spare fuses included with module. WARRANTY: Three years (excluding fuses). TAS Module Compatibility MODULE SSM-0/0 SSM-00 DSS-0/0 DSS-00 ALARM FUNCTIONS IDLE BOOST OFF Note: TAS module is not compatible with older CSS-G/0G or DSS-G/0G modules MODULE CSS-0/0 CSS-00 SSM-G SSM-G SSM-0G ALARM FUNCTIONS IDLE BOOST OFF BOOST BOOST The BOOST setting is the NORMAL setpoint plus 0, 0, or 0%; for example, if setpoint = 00 F and BOOST is 0%, then BOOST temperature = 0 F. NORMAL NORMAL NORMAL operation is as though the TAS module is not present. Remote Control Functions IDLE 9 C (00 F) or 00 C ( F) IDLE IDLE (Standby heat) reduces heat to 00 F or F. AMBIENT OFF OFF cuts power to the heater: The user can monitor cool down. TIME Upgrade Kits For Converting to Communications Mainframes MAIN FRAME MAIN FRAME CIK- CIK- CIK-7 CIK- CIK- CIK- CIK- CIK-0 CIK- -ZONE -ZONE 7-ZONE -ZONE -ZONE -ZONE -ZONE 0-ZONE -ZONE CIK- CIK- CIK- CIK-0 CIK- CIK- CIK-HP CIK-HP CIK-HP -ZONE -ZONE -ZONE 0-ZONE -ZONE -ZONE -ZONE HIGH POWER -ZONE HIGH POWER -ZONE HIGH POWER

36 Smart Series Microprocessor-Based Computer Interface Module CIM-0-0/0 The CIM Computer Interface Module is the communications link between CSS modules and a remote host system. Using SPI protocol, it permits downloading of setpoints from any SPI protocol-compatible molding machine. Control system status can subsequently be monitored via the machine s control panel. Up to zones of control can be accommodated with one CIM module. The CIM and CSS modules must all be installed in a communications-style mainframe. Features SPI protocol compatible Industry Standard Interfaces: EIA, EIA multidrop, EIA Simple to use requires no special training -zone communications capability Compatible with both Smart Series and G-Series communications-style (MFCP) Mainframes* *For use with CSS modules only. NOTE: Non-communications style Mainframes (MFP) may be upgraded to communications style (MFCP) with easy-to-install Communications Interface Kits (CIK) See page. Compatible Interfaces (jumper selected on module) RS (EIA) DUPLEX ft. max. RS (EIA) DIFFERENTIAL ft. max. multi-drop RS (EIA) DIFFERENTIAL ft. max. CIM - Computer Interface Module CIM00 CIM00 VOLTS 0 VAC 0 VAC FUSE REQUIREMENTS: () ABC- fuses WARRANTY: Three years (excluding fuses) Contact D-M-E for Cable Quotes Cables for RS, RS, and RS available by special order. NOTE: Standard (0 VAC) modules are compatible with mainframes wired for either 0 VAC three phase (standard) or 0 VAC single phase. Use CIM-0-0 for 0V operation. Front Panel Controls and Indicators:. DIGITAL LED DISPLAY: Multi-Function Display Indicates the Transmitted Data or Commands.. COMMUNICATIONS CONNECTOR: DB-9 style input/output connector. A duplicate of this connector is included at rear of module for those who prefer to route the computer interface wiring internally.. HANDLE: Assists in insertion or removal of module from mainframe.. POWER ON/OFF SWITCH: Controls AC power to the module.. PUSH-PULL FASTENER: Quickly locks module into mainframe. No tools required.. IDENTIFICATION LABEL: Lists module catalog number and power ratings for quick reference.

37 Replacement Parts and Service Items for D-M-E Smart Series Temperature Control Systems MOLD C (FEMALE) E (FEMALE) G (MALE) MAIN FRAME THERMOCOUPLE CABLES MOLD POWER CABLES B (MALE) D (FEMALE) A (MALE) F (MALE) H (FEMALE) I 7 9 A B C MOLD POWER INPUT CONNECTOR (FRONT) MOLD THERMOCOUPLE OUTPUT CONNECTOR (FRONT) NOTE: For upper inside communications connectors, see page Q- Connectors / Connector Kits ( - Zone, Amp; - Zone, 0 Amp) REFERENCE LETTER A B C D E F G H I DESCRIPTION Mold Thermocouple Output Connectors Mold Power Input Connectors Mold End Kit for -Zone Thermocouple Cable (0, or 0 AMP) Mold End Kit for -Zone Thermocouple Cable (0 or AMP) Mold End Kit for -Zone Thermocouple Cable (0 or AMP) Mold End Kit for all 0 or AMP Power Cables Mold End Kit for or -Zone 0 AMP Power Cables Mold End Kit for Zone 0 AMP Power Cables Frame End Kit for all Thermocouple Cables (0, or 0 AMP) Frame End Kit for all 0 or AMP Power Cables Frame End Kit for or -Zone, 0 AMP Power Cables Frame End Kit for -Zone, 0 AMP Power Cables Thermocouple Input Kit for all Mainframes (0, or 0 AMP) Power Output Kit for all 0 or AMP Mainframes Power Output Kit for -, or -Zone, 0 AMP Mainframes Power Output Kit for -Zone, 0 AMP Mainframes Edge Card Connector Kit for all Mainframe PC Boards (0, or 0 AMP) See pg. & See pg. 0 CKTF--G CKTF--G CKTF--G CKPF--BG CKPF--CG CKPF--CG CKTF--AG CKPM--BG CKPM--CG CKPM--CG CKTM--AG CKPF--BG CKPF--CG CKPF--CG CKF--G

38 7 Replacement Parts and Service Items for Smart Series Temperature Control Systems Mainframe, Cable Components, and Service Tools* CBD0M CBD0M CBD0M CBD0 CBD70 PIN-0 PIN-0 PIN-00 PIN-00 WHT-99 RPM-00 RPM-00 RPM-00 RPM-00 RPM-007 RPM-009 RPM-000 RPM-00 RPM-00 RPM-00 RPM-00 RPM-00 RPM-00 RPM-007 RPM-00 RPM-009 RPM-0070 RPM-007 RPM-007 RPM AMP POLE, CIRCUIT BREAKER USED IN MFPG AND MFPG 0 AMP POLE, CIRCUIT BREAKER USED IN MFRG 0 AMP POLE, CIRCUIT BREAKER USED IN MFFPRG AND MFHPG 0 AMP POLE, CIRCUIT BREAKER USED IN THROUGH ZONE MAINFRAMES 70 AMP POLE, CIRCUIT BREAKER USED IN THROUGH ZONE & HIGH POWER MAINFRAMES GAUGE MALE PIN FOR B & F POWER CONNECTORS (PACKAGE OF 0) GAUGE FEMALE SOCKET FOR D & H POWER CONNECTORS (PACKAGE OF 0) 0 GAUGE MALE PIN FOR G THERMOCOUPLE CONNECTOR (PACKAGE OF 0) 0 GAUGE FEMALE PIN FOR E THERMOCOUPLE CONNECTOR (PACKAGE OF 0) CRIMP TOOL FOR ALL PIN-XXXX LISTED ABOVE MALE/FEMALE EXTRACTION TOOL FOR ALL PIN-XXXX LISTED ABOVE NEON INDICATORS USED ON 0 VAC MAINFRAME CIRCUIT BREAKER PANELS CARD GUIDES FOR ALL MAINFRAMES PINS FOR WHITE EDGE CARD CONNECTORS I (PACKAGE OF 0) EXTRACTION TOOL FOR RPM-00 PANEL MOUNT BASE & LATCH FOR ZONE THERMOCOUPLE MOLD CONNECTION A PANEL MOUNT BASE & LATCH FOR ZONE THERMOCOUPLE MOLD CONNECTION A PANEL MOUNT BASE & LATCH FOR ZONE THERMOCOUPLE MOLD CONNECTION A MALE INSERT FOR ZONE THERMOCOUPLE MOLD CONNECTION A MALE INSERT FOR ZONE THERMOCOUPLE MOLD CONNECTION A MALE INSERT FOR ZONE THERMOCOUPLE MOLD CONNECTION A FEMALE INSERT FOR ZONE THERMOCOUPLE CABLE CONNECTOR C FEMALE INSERT FOR ZONE THERMOCOUPLE CABLE CONNECTOR C FEMALE INSERT FOR ZONE THERMOCOUPLE CABLE CONNECTOR C HOOD FOR ZONE THERMOCOUPLE CABLE CONNECTOR C HOOD FOR ZONE THERMOCOUPLE CABLE CONNECTOR C HOOD FOR ZONE THERMOCOUPLE CABLE CONNECTOR C HOOD FOR, & POWER & THERMOCOUPLE CABLE CONNECTIONS D, E & F MALE INSERT FOR B, F & G ( AMP CONNECTOR RATING IS EXCLUSIVE TO D-M-E) FEMALE INSERT FOR D, E & H ( AMP CONNECTOR RATING IS EXCLUSIVE TO D-M-E) *(Reference page - for Letter Designations) SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE SEE PAGE All Smart Series Modules ABC- ABC- ABC- ABC-0 ABC- NYL-000 RPM-000 RPM-0009 RPM-007 RPM-009 RPM-00 RPM-00 RPM-000 RPM-00 AMP 0 VAC FUSE AMP 0 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES AMP 0 VAC FUSE - NOTE: THESE LOWER POWER FUSES ARE RECOMMENDED FOR NOZZLES 0 AMP 0 VAC FUSE - NOTE: REQUIRED FOR AMP MODULES USED IN 0 AMP FRAMES AMP 0 VAC FUSE NYLATCH MODULE RETENTION PLUNGER AND GROMMET (0/PKG) - NOTE: AT THE BOTTOM OF EACH MODULE POWER ROCKER SWITCH FOR ALL MODULES EXCEPT DSS AND CSS- TRANSFORMER TYPE DST-- FOR ALL MODULES EXCEPT DSS & TAS ALUMINUM HANDLE FOR AMP MODULES 0 AMP POLE, CIRCUIT BREAKER FOR MODULES TRIAC - TYPE Q00P 0 AMP 00 VOLT FOR USE ON ALL MODULES TRIAC - TYPE BTA0-00B 0 AMP 00 VOLT FOR USE ON ALL MODULES EXCEPT CSS 00 OHM FLAME PROOF FUSIBLE LINK RESISTOR USED IN THERMOCOUPLE CIRCUIT (0/PKG) USED ON ALL MODULES A/D CONVERTER FOR SSM-G, SSMG, SSM-0G, SSH-00, SSH-00 AND ALL CSS MODULES

39 Replacement Parts and Service Items for Smart Series Temp Control Systems (Cont.) CSS-G, CSS-0G, CSS-0, CSS-00 CSS-000 CSS-000 RPM-00 RPM-00 RPM-00 RPM-00 MICROPROCESSOR FOR CSS-G MICROPROCESSOR FOR CSS-0 TRIAC DRIVER U OPTOCOUPLER U9 & U OPERATIONAL AMPLIFIER U & U OPERATIONAL AMPLIFIER U DSS-G, DSS-0G, DSS-0, DSS-00 DSS-000 DSS-000 RPM-000 RPM-00 RPM-00 RPM-00 RPM-009 MICROPROCESSOR FOR DSS-G, DSS-G & DSS-0G MICROPROCESSOR FOR DSS-0, DSS-0 & DSS-00 TRANSFORMER TRIAC DRIVER Q POWER ROCKER SWITCH MA TIME LAG FUSE F (USED IN DSS-0, 0, & 00 MODULES ONLY); CHECK YOUR MODULE! 00 MA TIME LAG FUSE F (USED IN DSS-0, 0, & 00 MODULES ONLY); CHECK YOUR MODULE! SSM-G, SSM-0G, SSH-00, ESH-0 SSM-000 RPM-000 RPM-00 RPM-00 RPM-00 RPM-00 MICROPROCESSOR TRIAC DRIVER U OPTOCOUPLER U & U7 OPERATIONAL AMPLIFIER U OPERATIONAL AMPLIFIER U SETPOINT POTENTIOMETER (FRONT PANEL) SSM-0, SSM-0, SSM-00, SSH-0, SSH-0, ESH-0 SSM-000 RPM-000 RPM-00 RPM-00 RPM-00 RPM-00 RPM-007 RPM-0090 MICROPROCESSOR TRIAC DRIVER U OPERATIONAL AMPLIFIER U & U PUSHWHEEL ASSEMBLY, WITH CABLE AUTO/MANUAL/AUTO% SWITCH FOR FRONT PANEL (SSM ONLY) (FRONT PANEL) AUTO/MANUAL/AUTO% SWITCH FOR FRONT PANEL (SSH & ESH) (FRONT PANEL) 0 MA TIME LAG FUSE F; CHECK YOUR MODULE! 0 MA TIME LAG FUSE F; CHECK YOUR MODULE! TAS-00, TAS-00, TAS-0, TAS-0 RPM-00 RPM-00 RPM-00 RPM-007 RPM-00 RPM-009 RPM-000 RPM-00 RPM-00 RPM-00 RPM-00 BEEPER TRANSFORMER SWITCH STANDBY HEAT (TAS-00, TAS-00, ONLY) & ALARM (ALL UNITS) (FRONT PANEL) ROTARY SWITCH FOR OFF, STANDBY HEAT, NORMAL, BOOST (TAS-0, TAS-0, ONLY) KNOB FOR RPM-007 RECEPTACLE CONNECTOR FOR FRONT PANEL MATING CONNECTOR (PLUG) FOR RPM-009 PINS FOR RPM-000 SOCKETS FOR RPM-009 RELAY # - ALARM OUTPUT CONNECTOR RELAY # - BEEPER CONTACTS

40 9 Input Power Wiring Diagrams (Option A) The diagrams on pages 9 through are printed on the back panels of the mainframes. For your convenience, they are depicted here along with additional information. For information on input wiring for 0 AMP mainframes, contact D-M-E. Standard input wiring for mainframes, unless specified otherwise at time of order, is 0 VAC, three- phase, -wire, 0/0 Hz. (OPTION A). If it becomes necessary to change to another configuration, refer to the appropriate diagram and information on the following pages: Page 9: (OPTION A) 0-0 VAC, -phase, -wire Page : (OPTION C) 0 VAC, single-phase, -wire Page 0: (OPTION B) 0- VAC, -phase, -wire Page : (OPTION D) 0-0 VAC, single phase, -wire 0 VAC, single-phase, -wire NOTE: For mold power and thermocouple connector wiring information, see pages -. OPTION A (Standard) 0-0 VAC, -Phase, -Wire Delta or Y Power Distribution System R/L S/L T/L 0 0 R/LMP/N WIRE X S/L 0 T/L FUSES NEON FAN CONTINUE ZONE ZONE ZONE ZONE ZONE ZONE A TERMINAL BLOCK GND GND MP/N R/L S/L T/L NC GND CIRCUIT BREAKER OV OV OV OV OV OV R/L S/L T/L As shown above, each module is powered from one of the three phases. Zone (), for example, is powered from Phase, which is supplied by R/L and S/L. Zone () is powered by Phase, which is supplied by S/L and T/L. Zone () is powered by Phase, which is supplied by R/L and T/L. NOTE: At this point, the sequence repeats itself. For example, Zone () is connected the same as Zone () to R/L and S/L and Zone () is connected the same as Zone () to S/L and T/L and Zone () is connected the same as Zone () to R/L and T/L. Zone (7) is then connected to the same phase as Zone () and (), etc. This method of connection assures the greatest likelihood of line balance.

41 0 Input Power Wiring Diagrams (Option B) 0 - VAC, -Phase, -Wire Y Power Distribution System WIRE X, 0 - MP/N + S/L 0 MP/N 0 R/L 0 T/L NEON FAN FUSES CONTINUE ZONE ZONE ZONE ZONE ZONE ZONE B TERMINAL BLOCK GND MP/N R/L S/L T/L GND CIRCUIT BREAKER OV OV OV OV OV OV MP/N R/L S/L T/L CAUTION NOTE: The voltages from line-to-line in this system are 0 to volts. Severe damage to module and mainframe could result if this type of AC input system is connected to a mainframe wired as OPTION A. This type of power distribution is not found or is very uncommon in the United States but is the most common system found in many other countries worldwide. WARNING: If export of this system is intended, make sure that wiring is reconfigured for the country where it is to be used. Please note that the 0- Volt Power Distribution System is the same as the Y connection shown in OPTION A except for the voltage levels and the use of the MP/N to develop the 0 volt from the 0- volt system. Notice that all modules have one line connected to MP/N and the other side connected to one of the three phase lines. Example: Zone () is connected to Phase, which is supplied by R/L and MP/N. Zone () is connected to Phase, which is supplied by S/L and MP/N. Zone () is connected to Phase, which is supplied by T/L and MP/N. Zone () starts the sequence over again. It is connected to Phase R/L and MP/N, etc.

42 Input Power Wiring Diagrams (Option C) 0 VAC, Two-Phase, -Wire WIRE X 0 + WIRE X 0 + R/L 0 MP/N 0 0 S/L NEON FAN FUSES CONTINUE ZONE ZONE ZONE ZONE ZONE ZONE C TERMINAL BLOCK GND MP/N R/L S/L T/L CIRCUIT BREAKER NC OV OV OV OV OV OV MP/N R/L S/L GND The 0 volt single-phase connection only uses two power lines plus ground. CAUTION: Only power conductors should be connected through the circuit breaker. Never make ground connections through a circuit breaker. Notice that the output of the circuit breaker is connected to terminal strips R/L and S/L. Also notice that ground is common with MP/N in this system. All zones in this system have to be connected to MP/N and either R/L or S/L. Line balance is achieved by alternating between R/L and S/L. Example: Zone () is connected to MP/N and R/L. Zone () is connected to MP/N and S/L, etc. Zone () starts the sequence over again. It is connected to MP/N and R/L, same as zone ().

43 Input Power Wiring Diagrams (Option D) 0-0 VAC, Single-Phase,-Wire or 0 VAC, Two Phase, -Wire WIRE X WIRE X 0 OR 0 + R/L 0 MP/N 0 0 S/L D TERMINAL BLOCK GND NEON FAN FUSES MP/N R/L S/L T/L FOR USE WITH 0V MODULE CONTINUE ZONE ZONE ZONE CONTINUE ZONE ZONE ZONE CIRCUIT BREAKER NC OV OV OV MP/N OV OV OV R/L S/L GND Above diagram depicts two different wiring configurations. One is 0-0 volt, singlephase, -wire. Note that lines R/L and S/L are connected through the circuit breaker to the appropriate terminal strips. All zones will be connected between R/L and S/L. MP/N is common with ground and is not connected through the circuit breaker. In the 0 volt connection (zone connections shown within the dashed-line area), the 0 volts is developed between R/L and MP/N and S/L and MP/N. Again, ground and MP/N are not connected through the circuit breaker. Each zone in this system will be connected to MP/N and either R/L or S/L. Line balance is achieved by alternating between R/L and S/L. Example: Zone () is connected to MP/N and R/L. Zone () is connected to MP/N and S/L, etc. Zone () starts the sequence over again. It is connected to MP/N and R/L, same as zone ().

44 D-M-E Company World Headquarters 9 Stephenson Highway Madison Heights, MI toll free tel -0- toll free fax info@dme.net web D-M-E of Canada, Ltd. 0 Northwest Drive Mississauga, Ontario, LV J toll free tel toll free fax info@dme.net web D-M-E Europe D-M-E Belgium C.V.B.A. Industriepark Noord B-00 Mechelen, Belgium --0 tel -- fax dme_europe@dmeeu.com