Specialized Design

Fast Heat combines our knowledge of heat, heaters and sensors in the hot runner business with our 30 years experience in controls to develop the most reliable control system available today.

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R 3 ? Right information at the Right time in the Right place

Time is the most critical component in the molding environment. We ensure that when we deliver our product it fits with our core design belief to deliver the right information at the right time in the right place ? with simplicity. Each time a Pulse is approached by an operator the use is intuitive and the information provided is timely and clear. We measure our success in achieving this goal in two ways:

•  Learn to use in 10 minutes or less. Using our Quick Start-Guide, an operator can set up a file, set the systems parameters and run the controller in 10 minutes or less. Fast Heat has tested this on numerous study groups to ensure effective human interaction.

•  Customer testimonials.

Human Factor

Every injection-molding machine creates lots of information every second of operation. Each moment an operator needs to make critical decisions based on that information.

Fast Heat has recognized that the critical component to every Hot Runner control system is the operator. As we add new features and functionality to the Pulse every new feature is analyzed not only for what the feature is intended to do but also how the operator interacts with that feature.

Instant Diagnostics

Our Instant Diagnostics indicate whether there is an open or Rev TC, open heater, triac short or over/under set point for temperature, % power and amperage. Open circuits and reverse thermocouples are detected and reported immediately without having to apply power to the hot runner. Tool rooms often use the Pulse for inspection prior to sending a tool to the production floor. It is quick and easy to use.

FT 2 : Fast-Tune Technology

To provide seamless control stability to all Hot Runner load applications, we have implemented a technology road map that meets today?s requirements for smaller, faster and more efficient load conditions. With this road map, we have a better understanding of where loads are today and where they are going to be in the future giving us the ability create a more robust tuning technology.

With every Pulse series control we offer Fast Tune Technology (FT 2 ), which combines over 30 years of control design experience with today?s technology requirements. We recognized early on that startup time is at a premium and having to wait for the control to ?tune? itself for up to 30 minutes is unacceptable. Fast Heat?s Fast Tune Technology does not require any special tuning time at startup. Simply running the controller will automatically activate FT 2 and once on it will constantly monitor and control a diverse set of load conditions ? all of the time.

Thermocouple Management: Slaving

We recognize that sensors are one of the most inexpensive replacement components, but can cause the most expensive downtime if they fail prematurely. We also recognize that sensors can be the weakest link in any hot runner system and have taken steps to not only ensure that the sensors are properly managed with status indicators and alternative operational functions but also built-in the ability to protect them.

To properly manage thermocouples we offer:

•  Sensor failure detection of open and shorted thermocouples (Instant Diagnostics).

•  If the thermocouple fails, there are three levels of control which keep the tool running.

•  Auto Slave

•  When AutoSlave is activated in conjunction with FT 2 , the Pulse will automatically select the next best load to automatically slave the heater output of the failed sensor zone.

•  The selection process is based on a ?best? load and setpoint program that is run during the Fast Tune process when selected.

•  If there is no load that matches that zones? criteria, the next best compensation will be AutoComp or a ?bumpless transfer? to manual power mode.

•  AutoSlave offers the best form of backup for a failed sensor since it automatically tracks the failed zones power by ?borrowing? another zones thermocouple. Doing this allows for a dynamic movement of power that will react to external changes from the molding environment like changes in water temp, chiller temps, pressure, feeds etc?

•  Auto Comp (Auto Compensation)

•  Through an advanced averaging process, if a zone looses a thermocouple the last average power setting is then applied to the load.

•  AutoComp is the industry standard in backup running modes that allow the zone to continue to process plastic. It offers a static output that will in some cases allow the drop to continue to run production.

•  Manual Slaving

•  If required, any zones? output can be manually slaved to another zone. This can be done to resolve failed sensors or as a temporary solution for ?cross-talk?. It can also be used as a way of increasing the power applied to a larger manifold zone without having to purchase a 30 Amp power module.

Thermocouple Management:

Active Thermocouple Protection (ATP) patent pending

Most controllers tell you when a problem occurs and offer some general corrections like AutoComp but the Pulse proactively protects one of the most common modes of failure in thermocouples with our patented ATP circuitry. Over 40% of all thermocouple errors occur as open thermocouples, most of which are related to a ground leakage error. This ground leakage occurs when there is a poor or missing ground between the tool and the hot runner controller. The end result is that leakage current is then passed through the next best ground point which is through the negative lead in the thermocouple. This is a problem for the thermocouple primarily due to its construction. Internally to the thermocouple the weakest link is the junction point between the large and small diameter wiring. So when any ground fault current is passed through this junction, inevitably the small wire fails similarly to a fuse blowing. ATP assists in preventing this catastrophic failure from occurring by actively absorbing the ground leakage current and in some cases temporarily opening a circuit on our Thermocouple module. The result is a longer lasting thermocouple over the running life of the tool.

Thermocouple Management: TC Rewiring

There are two driving factors in having an option to rewire a hot runner tool.

• A significant amount of zones, usually greater that 32
• Time factor to identify and rewire mis-wired thermocouple zones

Though most systems offer an automated rewiring analysis, in most cases this does not work correctly due to a diverse set of load conditions seen in the tool, where the resultant selection done by the controller is worse than the original wiring issue to start with.

The Pulse offers a simple manual selection mode where any zones? thermocouple can be moved or swapped with any other zone. This offers the maximum in flexibility along with the security of ensuring a good selection without the risk of severely damaging the hot runner system. The manual detection process involves using the View mode while methodically applying power to individual zones.

Embedded Technology - Reliability. Always.

Downtime is not an option. With the Pulse HRC system, we have taken a completely different approach to ensuring trouble-free operation in the harshest of environments.

In a typical molding environment there is exposure to heat and vibration; both of which are disastrous to any PC exposed in that environment. The common modes of failure with a PC based controller are:

• Moving parts like a hard drive
• Commercial ?off the shelf? motherboards
• Canned or off-the-shelf operating environments like DOS or Windows

Hard drives and commercial motherboards have a life span that is specified by normal operating conditions in an office environment, but when exposed to an industrial environment the life is significantly reduced from over / under voltages, excessive heat, vibration, brown outs or power outages.

Off the shelf operating systems are designed to handle a wide variety of applications, but unfortunately are not specifically designed what most controllers need to be done well and that is Hot Runner Temperature System control.

Fast Heat views the Hot Runner Temperature control as mission critical and in all cases must be kept running under the most adverse conditions. With that mission in mind we set out to develop from the ground up a robust system that is designed for what it is intended to do.

To accomplish this we use an embedded architecture from the ground up. Where we ensure that every aspect of the control is designed to accomplish its task in the environment in which it will be used. As a result each board is designed and built by Fast Heat; no moving parts are used for control like hard drives ? memory is in flash. The Pulse operating system is a real time system that is not prone to the problems of crashing as in Windows or DOS operating systems.

Robust technology is at the core of each of our products. By clearly understanding the environment of use and needs of the customer we design each product to do its job well, 24 hours a day without stopping.

At-Temperature Output

As time goes on, the materials are not only more expensive but have tighter processing tolerances and requirements that push the limit in molding. As a result, the old habits of yesterday don?t apply to today?s environment. We recognize this shift in technology and understand that changing the habits of the past are required with speed and tact to ensure a successful product run with each job.

By working closely with our customers, we recognized one of the toughest startup problems is starting a tool that has not been properly soaked prior to making the first shot. If a tool is shot without the hot runner being properly brought up to temperature the first shots of material will be scrap and depending on the shot size could cost hundreds of dollars. More importantly with an improperly heated hot half shooting plastic can cause costly catastrophic failures such as breaking the screw in the injector.

To prevent this, the Pulse incorporates an At-Temperature Output that when tied into the injection molding machine will inhibit shot input. When combined with the SOFT SOAK timer, this can further ensure that the tool is properly soaked and ready to shoot, minimizing on pre-shots and possible costly repairs.

Hot-Swappable Modules

Time is critical when a module has blown a fuse or lost a triac. Replacing the module quickly is the fist thing on the molders mind. However, most of the time the molder does not have the time to think to shut off the controller prior to removing and/or inserting a new module.

The results from plugging in or removing a module under power is catastrophic to the module and the controller primarily blowing the card edges on both module and the cabinet. The result is a non-functioning cabinet and a control module destroyed beyond repair.

Through our experience in repairing these modules, we innovated and found a way to protect the cards from this catastrophic failure. Each power module is equipped with a circuit and configuration that protects the card edges on both the module and control cabinet.

Bake-Out

Most Hot Runner components are designed to withstand the harshest of environments while delivering a precise amount of heat. This causes some designs to achieve a balance between isolation to ground or ground leakage from the heating element. The largest contributors of ground leakage are tubular heating elements in a manifold. The result of running a heater with a ground fault can in most cases be catastrophic to the heater and the control module where in most cases each will fail beyond repair.

To prevent this from occurring, the Pulse has a Bake-out feature provides a small amount of power is applied at start-up with a gradual increase to assist in baking out any ground fault present in the heating elements.

Evensoak

Leaking a system due to improper startup sequence of the hot half is one of most common errors that occur. In most cases the explanation is that the operator forgot to turn on the manifolds first. When activated, Evensoak will automatically do this for the molder every time RUN is pressed.

Hot runner designs are becoming more sophisticated every day. This has increased the demand for grouped start-ups. The Pulse HRC allows the operator to define groups within a tool to automatically start 1 st , 2 nd , 3 rd , etc. This allows for proper expansion which prevents leakage and reduces hot runner wear. This wear is often seen at the seal-off diameter around nozzles and on the surface of the manifold. Other benefits include minimizing material degradation, additional safety by reducing hot material release from gates and minimizing peak amperage draw during start-up (see Fast Heat Power Management System).

Security

In the molding environment today there are multiple levels of operation with he most critical being the operator. Since it is up to the operator to ensure the tool is running throughout the day, it is critical that they are given the ability to make choices like changing setpoints or turning a zone from automatic mode to manual mode.

In most cases operators learn through trial and error on their part either from a lack of knowledge or training. In some cases this can be a good thing causing them to learn more about the process but in most cases it can be dangerous because some of the settings in the hot runner control can cause a significant amount of damage.

We recognized this early on and have implemented a multilevel security system for those mission critical applications that require some adjustments to be locked out of reach.

Within the Pulse is a multi level security system that allows the supervisor / manager to restrict access to certain parts of the Pulse operation and setup. Up to two different levels of security can be assigned with 5 users under each level with their own security code.

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