Altanium Neo5

User Guide

Original Instructions
 v 2.0 — January 2023 Altanium Neo5

Issue: v 2.0 — January 2023

This product manual is intended to provide information for safe operation and/or
maintenance. Husky reserves the right to make changes to products in an effort to
continually improve the product features and/or performance. These changes may result in
different and/or additional safety measures that are communicated to customers through
bulletins as changes occur.
This document contains information which is the exclusive property of Husky Injection
Molding Systems Limited. Except for any rights expressly granted by contract, no further
publication or commercial use may be made of this document, in whole or in part, without
the prior written permission of Husky Injection Molding Systems Limited.
Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission
to its customers to reproduce this document for limited internal use only.
Husky® product or service names or logos referenced in these materials are trademarks of
Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies
under license.
All third-party trademarks are the property of the respective third-party and may be
protected by applicable copyright, trademark or other intellectual property laws and treaties.
Each such third-party expressly reserves all rights into such intellectual property.
© 2022 Husky Injection Molding Systems. All rights reserved.

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User Guide v 2.0 — January 2023 Altanium Neo5

General Information

Telephone Support Numbers

North America Toll free 1-800-465-HUSKY (4875)

Europe EC (most countries) 008000 800 4300

Direct and Non-EC + (352) 52115-4300

Asia Toll Free 800-820-1667 or +800-4875-9477

Direct: +86-21-3849-4520

Latin America Brazil +55-11-4589-7200

Mexico +52-5550891160 option 5

For on-site service, contact the nearest Husky Regional Service and Sales office.
For non-emergency questions and issues, e-mail Husky at [email protected].

Husky Regional Service and Sales Offices

For the nearest location, please visit www.husky.co.

Product Upgrades
Upgrades are available that can improve output, reduce cycle times, and add functionality to
Husky equipment.
To see what upgrades are available, visit www.husky.co or call the nearest Husky Regional
Service and Sales Office.

Ordering Spare Parts

All spare parts for Husky equipment can be ordered through the nearest Husky Parts
Distribution Center or online at www.husky.co.

Ordering Additional Manuals

Additional copies of this manual and other documentation can be purchased through the
nearest Husky Regional Service and Sales office.

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Table of Contents

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Telephone Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Husky Regional Service and Sales Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Product Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Ordering Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Purpose of the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Restrictions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Input Wiring (Conventional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Environmental Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Equipment Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Controller Lifting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8.1 C6-1 and C6-2 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8.2 Single Stack Lifting Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 2: Hot Runner Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Types of Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.1 Open Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Configuring Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2.1 Configuring a Zone for Zero Cross Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2.2 Configuring a Zone for Phase Angle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.3 Determining the Heater Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.4 Thermocouple Types and Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Chapter 3: Connecting the System to the Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 Prior to Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Connecting to the Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3 Startup Procedure Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.4 Supply Voltage Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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Chapter 4: Altanium Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2 Operator Interface — Screens and Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.1 Dialog Box — Accept/Cancel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.2 Home Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.2.1 Basic/Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2.3 Header and Footer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.3.1 Header — Controller Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.2.3.2 Header — System Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.2.3.3 Header — Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2.3.4 Footer — Alarm Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.2.3.5 Footer — System and User Management Buttons. . . . . . . . . . . . . . . . . . . . .25
4.2.4 System Screen Selections — Zone Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.2.5 System Screen Selections — Temperature Management. . . . . . . . . . . . . . . . . . .27
4.2.6 System Screen Selections — Data Collection and Monitoring . . . . . . . . . . . . . .27
4.2.7 System Screen Selections — System Configuration . . . . . . . . . . . . . . . . . . . . . . . .29
4.3 System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.4 Screen Keyboards, Keypads, and Selection Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.4.1 Keypad Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.4.1.1 Enter a Specified Setpoint Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.4.1.2 Increase or Decrease a Setpoint by a Specified Value. . . . . . . . . . . . . . . . . .33
4.5 Save Now . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.6 Save a Dialog Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Chapter 5: Security and Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.1 Log In/Log Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.2 User Management and Security Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2.1 Manage Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2.1.1 Add a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
5.2.1.2 Delete a User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.2.1.3 Change a User Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.2.2 Set the Security Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.2.3 Security Assignments Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.2.4 Enable Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.2.5 Security Settings List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Chapter 6: Customize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6.1 Customize Screen Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.1.1 Advanced Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.2 Basic Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
6.2.1 System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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6.2.2 Import/Export Customize Screen Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

6.2.2.1 Export Customize Screen Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
6.2.2.2 Import Customize Screen Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
6.2.3 Assign Advanced or Basic Mode to a User Profile . . . . . . . . . . . . . . . . . . . . . . . . . .77
6.2.3.1 Assign a Mode to a User Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
6.3 Default Screen Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
6.3.1 Default Setup Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
6.3.2 Default Settings Screen Default Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
6.3.3 Import/Export Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
6.3.3.1 Export Default Screen Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.3.3.2 Import Default Screen Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Chapter 7: Mold Setups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.1 File Management Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.1.1 Save Changes to a Mold Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.1.2 Save the Current Mold Setup File as a New File . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.1.3 Load an Existing Mold Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
7.1.4 Delete Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.1.5 Copy Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.1.6 Transfer Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.1.6.1 Transfer Data to the Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.1.6.2 Transfer Data Using a USB Storage Device . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Chapter 8: Process Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

8.1 Zone Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
8.2 Zone Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
8.2.1 Make Zone Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
8.2.2 Add Zones to Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
8.2.3 Remove a Zone from a Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.2.4 Delete a Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.3 Multi-Group View Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.3.1 Group Controller Function Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.3.2 Define Group Layout Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.3.3 Change Header Colors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.3.4 Collapse and Expand Zones Shown in a Group . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.4 Neo View Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.5 Text View Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.5.1 Zone Selection on the Text View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.5.2 Sorting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.6 Quick Adjustment Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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8.7 Quick Set Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

8.7.1 Frequently Used Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.7.2 Zone Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.7.2.1 Zone Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.7.2.2 Locked/Unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.7.2.3 Display/Hide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.7.3 Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.7.4 Setpoint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.7.5 Manual Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.7.6 Manual Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.7.7 Remote Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.7.8 Remote Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.7.9 Heater Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.7.10 Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.7.11 Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.7.12 ART Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8.7.13 Zone Follower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.7.13.1 Using the Automatic Follower Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.7.13.2 Manually Setting One Zone as a Follower to Another Zone. . . . . . . . . . 131
8.8 Alarm Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.9 Zone Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.10 Active Reasoning Technology (ART) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.10.0.1ART Fault Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.10.0.2Altanium Card ART Process Time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.10.0.3ART Parameters Save and Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.10.1 Changing the Zone Control from ART to PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.10.2 Typical PID Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.10.2.1Possible Causes of Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.11 ART 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Chapter 9: Mold Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

9.1 Test Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
9.2 Mold Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.2.1 Zone Cooling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.2.2 Maximum Test Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.2.3 Test Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.3 Mold Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.3.1 Automatic Thermocouple Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.3.2 Compare Mold Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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Chapter 10: Heat the Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

10.1 Neo5 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.1.1 Heat Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.2 Earth Leakage/Wet Heater Bake Out System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10.2.1 Earth Leakage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10.2.2 Configure the Length and Number of Bake Out Cycles . . . . . . . . . . . . . . . . . . . 152
10.3 AltaStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.4 UniStart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.5 Fast Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.6 Soft Start Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.6.1 Adjusting the Soft Start Minimum Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.7 Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.7.1 Opening the Alarm Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.7.2 Clearing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.8 Event History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.8.1 Filtering Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.9 Alarm Conditions — Warning Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.10 Abort Conditions — Shutdown Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Chapter 11: System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

11.1 System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.2 Changing the Number of Zones in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Chapter 12: Staged Startup and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

12.1 Enabling or Disabling Staged Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
12.2 Setting Soak Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
12.3 Set the Stage Temperature and Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Chapter 13: Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

13.1 Process Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
13.1.1 Change the Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
13.1.2 Change the Graphic Process Traces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
13.1.3 View a Specific Point on the Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
13.2 Power Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
13.2.1 Configure the Power Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
13.2.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.3 CAN Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Chapter 14: Data Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

14.1 Select Reports, Process Data, and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
14.2 Report Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Chapter 15: Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

15.1 Digital I/O Connector Pin-Out Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
15.1.1 Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
15.1.2 Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
15.1.3 Input Connector Pin-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
15.1.4 Output Connector Pin-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Chapter 16: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

16.1 Servicing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
16.2 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
16.2.1 Cable Connections — Integrated Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 200
16.2.2 Cable Connections — Freestanding Configuration . . . . . . . . . . . . . . . . . . . . . . 201
16.3 Intelligent Control Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
16.3.1 Replacing an Intelligent Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
16.3.2 Replacing a Blown Fuse on an Intelligent Control Card. . . . . . . . . . . . . . . . . . . 206
16.4 Neo5 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
16.4.1 Replacing the Touch Monitor — Integrated Configuration . . . . . . . . . . . . . . . 209
16.4.2 Replacing the MCU — Integrated Configuration. . . . . . . . . . . . . . . . . . . . . . . . . 213
16.4.3 Replacing the Touch Monitor — Freestanding Configuration . . . . . . . . . . . . 217
16.4.4 Replacing the MCU — Freestanding Configuration . . . . . . . . . . . . . . . . . . . . . . 221
16.4.5 Replacing the Operator Interface — Freestanding Configuration. . . . . . . . . 225
16.5 Neo5 Mobile Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
16.5.1 Installing Neo5 on the Mobile Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
16.6 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
16.6.1 Mainframe (Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
16.6.2 Touch Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
16.7 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Appendix A: Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

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Chapter 1 Introduction

This user guide includes general warnings and cautions to avoid injury to personnel and
damage to the system. These warnings and cautions are not intended to be, nor are they all-
inclusive to every condition or application that may occur during operation. Maintenance
and safety procedures remain the sole responsibility of the individual and his or her
company.

IMPORTANT!
Some manuals may contain addendums that detail new or updated information.
Before reading a manual, make sure to review all available addendums located at the
end of the manual.

1.1 General Safety

WARNING!
Electrical shock risk-de-energize controller prior to connecting, disconnecting, or
servicing the controller, hot runner or mold.

WARNING!
Electrical hazard - risk of shock or personal injury. ALWAYS ensure that the screw on
the back of the top portion of the controller, marked with the general warning symbol,
is installed when the controller is energized. This is the grounding point for the top
cover to the chassis. Removal of this screw could cause an unsafe condition unless
proper precautions are taken such as, Lock Out Tag Out (LOTO).

WARNING!
Gas/vapor hazard – risk of respiratory injury. Certain processed materials could release
harmful gas, vapors, or dust. Install an exhaust system according to local codes. Plastic
degrades with prolonged exposure to the setpoint temperature. Do not leave machine
and controller unattended.

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• The system should only be installed by qualified personnel in accordance with local
codes.
• When the controller is connected to an Injection Molding Machine (IMM), the safety of
the system is the responsibility of the integrator.
• Only persons with a thorough knowledge of the system's operation and capabilities
should operate the system.
• Read all of these instructions before connecting power and turning on the system.
• Follow all warnings and instructions marked on the system.
• Unless specifically explained in this manual or directed by Husky, do not attempt to
repair the system. Doing so could result in damage to the system, or serious personal
injury.
• Only use the specified input supply voltage that is indicated on the identification label
attached to the power input cable and/or the cabinet
NOTE: If unsure of the appropriate supply voltage, call the nearest Husky Regional
Service and Sales office.

CAUTION!
Mechanical hazard – risk of damage to the equipment. NEVER allow the fan inlets or
outlets on the unit to become blocked. Insufficient cooling airflow through the fan
inlets and outlets could damage the system.

CAUTION!
When switching OFF the system wait 30 seconds before switching the main disconnect
back ON. If you do not wait the required 30 seconds, communication issues may occur.

1.1.1 Safety Signs

Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety
of personnel involved in equipment installation, operation, and maintenance, use the
following guidelines:
The following safety symbol may appear on safety signs:
NOTE: Safety signs may include a detailed explanation of the potential hazard and
associated consequences.

Safety Symbol General Description of Symbol

General
This symbol indicates a potential personal injury hazard. It is usually
accompanied by another pictogram or text to describe the hazard.

Hazardous Voltage
This symbol indicates a potential hazard that may cause death or serious injury
and will appear on any panel that, if removed, will expose the user to more
than 40 VAC.

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1.2 Purpose of the Equipment

Husky controllers are designed to control the process temperature for injection molding
applications only.
Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky
product for anything other than its intended use.

1.3 Restrictions of Use

Husky injection molding equipment must never be:

• used for any purpose other than that described in Section 1.2, unless otherwise
approved by Husky
• operated or serviced by personnel unfamiliar with the inherent risks and necessary
precautions related to controllers

1.4 Input Wiring (Conventional)

Table 1-1 summarizes the wiring conventions used.

Table 1-1 Electrical Wire Standards

Description Wire Color

Neutral Blue

Earth/Ground Green/Yellow Green

Line Black Black

Line Brown Red

Line Gray White

DANGER!
Electrocution and/or mechanical hazard - risk of death or serious injury and possible
damage to the equipment.
Incorrectly wiring the controller could cause death or serious injury and/or damage to
the controller or hot runner. Only qualified personnel should connect the electrical
power supply. All work must conform to applicable local electrical codes.

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1.5 Environmental Operating Specifications

The environmental operating specifications that follow for the Altanium Neo5 operator
interface:

CAUTION!
Mechanical hazard – risk of equipment damage. Falling or spraying liquid, including oil
or water, could damage the equipment. Do not spray wash.

• For Indoor use only.

• Operating Temperature: 5 to 40 °C (41 to 104 °F)
• Operating Humidity: 0% to 90% RH, Non-Condensing
• Altitude: up to 2000 m (6562 ft)
• Pollution Degree: PD2
• Overvoltage Category: OVII

1.6 Equipment Ratings

Ratings for the entire Neo5 can be found on the nameplate attached to the back of the
controller.
The equipment ratings that follow are for the Neo5 operator interface only:
• Supply Voltage: 100 to 240 VAC +/- 10%, single phase
• Frequency: 47 to 63 Hz
• Power Rating: 130 W

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1.7 Weights and Dimensions

The technical specifications (weights and dimensions) for the most common Altanium Neo5
configurations are shown in Table 1-2.

Table 1-2 Neo5 Configuration Weights and Dimensions

Configuration Dimensions Weight

Neo5 Operator Interface • Width: 278 mm (11 in) • Controller: 7.25 kg (16 lb)
• Depth: 363 mm (14 in) • With shipping container:
• Height: 324 mm (13 in) 3 kg (27 lb)

Neo5 C6-1 (1 Bay) • Width: 305 mm (11.4 in) • Controller: 25.40 kg (56 lb)
• Depth: 331 mm (13 in) • With shipping container:
• Height: 407 mm (16.0 in) 40.82 kg (90 lb)

Neo5 C6-2 (2 Bay) • Width: 305 mm (11.4 in) • Controller: 35.38 kg (78 lb)
• Depth: 331 mm (13 in) • With shipping container:
• Height: 635 mm (25.0 in) 59.87 kg (132 lb)

Neo5 Single Stack • Width: 450 mm (17.7 in) • Controller: 65.32 kg (144 lb)
• Depth: 560 mm (22 in) • With shipping container:
• Height: 1512 mm (59.5 in) 133.36 kg (294 lb)

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1.8 Controller Lifting Instructions

The recommended lifting method varies depending on whether the Altanium Neo5 is a C6-
1, C6-2, or single stack (freestanding) controller.

1.8.1 C6-1 and C6-2 Lifting Instructions

Use the steps that follow to correctly lift a Neo5 C6-1 or C6-2:

1.8.2 Single Stack Lifting Instructions:

Lifting devices (crane or forklift) and straps vary in lifting ability and lengths. See the table
that follows for the correct lifting ability and lengths.

Webbed Straps Rated 2903 Lifting Device (Lifting

Altanium Controller Ratchet Strap
kg (6400 lb) Ability)
Neo5 Single Stack Two, 2.44 m x 25.4 mm One, 1.52 m (5 ft) 227 kg (500 lb)
(8 ft x 1 in.)

Do the steps that follow to lift the single stack Neo5:

1. Place each of the webbed straps under the controller. See the table above for the correct
strap lengths.
a. For a single stack Neo5, the webbed straps go under the equipment from left to
right.

2. Bring the straps up and above the Neo5 and attach them to the lifting device.

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a. Make sure the straps are positioned between the caster wheels and the retaining
brackets under the base of the controller.

b. Make sure the straps are not pinching or crushing any cables attached to the Neo5.

3. Use the lifting device to apply enough upward force on the straps to remove the slack,
but do not lift the Neo5 at this time.
4. Place the ratchet strap around the top of the Neo5, holding the four ends of the webbed
straps. Do not tighten the ratchet strap at this time.
NOTE: The ratchet strap keeps the controller from tipping when the Neo5 is lifted.

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5. Place cloth or other cushioning material between the ratchet strap and the Neo5 to keep
the finish free from rubs and scratches.

6. Tighten the ratchet strap.

7. Use the lifting device to slowly lift the Neo5 off the ground a few inches.
8. Check the webbed and ratchet straps to make sure that the Neo5 will not tip.
9. Move the Neo5 to the new location.
10. At the new location, slowly lower the Neo5 to the ground.
11. Remove the ratchet straps, cushioning material, and webbed straps.

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Chapter 2 Hot Runner Temperature Control

This guide is designed to make sure that users receive the maximum possible benefit from
the use of the Neo5.
The Neo5 was designed as a processor's tool for hot runner molding. The fundamental
criteria required to operate a hot runner mold is controlling the process temperature so that
it is consistent and repeatable with respect to the process setpoint. The closer to the setpoint
the process temperature is maintained, the lower the setpoint temperature may be set. This
equates to less cooling time required (energy in - energy out), and faster cycle times.

2.1 Types of Temperature Control

Controllers use two basic types of control:

• Open loop control with no thermocouple feedback.
• Closed loop control with thermocouple feedback. Closed loop can be sub-categorized
as follows:
- Internal Thermocouple - Located inside and as part of the heater assembly.
- External Thermocouple - Located close, but not actually part of the single heater
assembly. The external thermocouple may be allocated to a group of heaters to
form a zone.

2.1.1 Open Loop Control

Without a thermocouple, it is not possible to control the temperature inside the mold, only
the amount of power supplied to the heater. The Neo5 maintains this power output
accurately with a resolution of 0.1%. This method of control is called manual regulation.
Open loop control is normally associated with tip heaters because the size of the tip heater
is too small for an internal thermocouple.

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2.2 Configuring Zones

In an effort to match the energy input requirements of differing types of loads, it is necessary
for the output power delivered to the heaters to be adjusted over a range of 0 to 100%. The
Neo5 can be set up to achieve this by using either Zero Cross Control or Phase Angle Control.

2.2.1 Configuring a Zone for Zero Cross Control

This method defines how the power to each heater is averaged over a period of time. This is
achieved by switching between complete half cycles of the heater supply voltage using a
snubberless TRIAC as a switching device.

2.2.2 Configuring a Zone for Phase Angle Control

This method defines how the power to each heater is adjusted, by varying the point in each
half cycle at which the snubberless TRIAC (switching device) is turned on.
In either control method, the Neo5 recalculates the power output requirements for the entire
system every 250 milliseconds to obtain the maximum control resolution. By combining
either of the above control methods with the Active Reasoning Technology (ART) control
algorithm, it is possible to achieve accurate temperature control of ± 1 digit under steady
state conditions.

2.3 Determining the Heater Size

Hot runner molds can have a number of different types of heating elements:
• Integral, which is a part of the probe.
• Cartridge, which is slid into the probe or directly into the mold steel.
In the manifold, a series of cartridge heaters or bent tubular style heaters are normally used.
The wire inside an element is typically made of nickel-chrome, which is then surrounded by
magnesium oxide. The size of this wire and number of turns determine its resistance, which
in turn determines its wattage (the amount of energy). This determines its performance in
the mold. Undersize heating elements (too little wattage) create a serious problem when the
control asks for power, and none is available. In almost all cases it is better to be oversize than
undersize in a hot runner mold.

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The Neo5 will provide wattage, resistance, or amperage information for heaters, if equipped
with intelligent control cards: X ICC2 or H ICC3. Alternatively, this information can be
determined using Ohm’s Law. The steps and formulas that follow demonstrate how:

WARNING!
Electrical hazard– risk of death or serious injury. Disconnect all electrical power from
the mold and controller prior to performing this test.

1. Using a multimeter, set the selector to measure resistance.

2. Connect the (red) positive lead to the first wire from the heating element and connect
the (black) negative lead to the second wire. The leads may be pins on a connector, or
the zone output fuses in the system as long as they are connected to the heating
element.
The meter will show a resistance in ohms. Record this measurement on a piece of paper.
Ohm's Law says:

Amps = Watts / Volts Amps = Volts / Resistance

Resistance = Volts / Amps Watts = Volts x Amps

Example: If the resistance is 12.5 ohms, and the input voltage is 240 volts, divide 240 by 12.5
to calculate the maximum amperage draw on that heating element:
240 / 12.5 = 19.2 amps
19.2 Amps x 240 volts = 4,608 watts.
In hot runner molding, some portions of Ohm's Law are more useful than others. We have
only presented here those laws that apply.

Input voltage 24 V 110 V 208 V 220 V 240 V

Resistance 20  20  20  20  20 

Amperage 1.2 A 5.5 A 10.4 A 11.0 A 12.0A

Watts 28.8 W 605.0W 2163.2 W 2420 W 2880 W

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2.4 Thermocouple Types and Color Codes

The Neo5 uses the ANSI color code for all thermocouples. The following table is provided as
reference for hot runners and cables that follow other color code standards.

International
Color Code BRITISH U.S. GERMAN
Code Type
(BS4937 Part (BS1843:1952) ANSI DIN
30:1993)
J Iron/ Overall Black Overall Black Overall Black Overall Blue
Constantan/
+ ve - ve + ve - ve + ve - ve + ve - ve
(Copper-
Nickel) Black White Yellow Blue White Red Red Blue

K Nickel- Overall Green Overall Red Overall Yellow Overall Green

Chromium/
+ ve - ve + ve - ve + ve - ve + ve - ve
Nickel-
Aluminum Green White Brown Blue Yellow Red Red Green

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Chapter 3 Connecting the System to the Mold

This chapter describes the connection to a power source and the checks to make before you
start the system.

3.1 Prior to Startup

DANGER!
Electrocution hazard – contact with hazardous voltages will cause death or serious
injury. Make sure that the system is completely disconnected from the power source.

• Clean up any water, oil, dirt, cleaning fluids, etc. that may have spilled during a mold
change or since the last production run.
• Make sure the display module is mounted to either the controller or remotely.
• Make sure that the cooling fan is free from obstruction.
• Check all of the cable connections between the system and the mold (if required). Make
sure all of the cables are free from wear or damage.
• Check that the earth/ground connection is in good condition. Make sure that the system
and the mold have the same ground reference.

3.2 Connecting to the Power Source

DANGER!
Electrocution hazard – contact with hazardous voltages will cause death or serious
injury. Make sure that the system is completely disconnected from the power source.

1. Connect the thermocouple and power output cables (if required).

2. Using an ohmmeter, touch one test lead to the mold and the other to the mold ground
terminal on the system. The resistance must be less than 1.
3. Make sure that the main input power disconnect is in the OFF position.
4. Connect the controller to the power source.

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3.3 Startup Procedure Checklist

WARNING!
Trip hazard – risk of death or serious injury. Make sure that all the cables between the
controller and all the external devices and/or equipment are marked clearly. Or route
the cables so that no one will trip over the cables.

Item Step 
1 Connect power/thermocouple cables between the mold and controller (if
required).

2 Connect the I/O box or option cables (if required).

3 Connect the controller to the power source.

4 Switch the controller ON.

5 Login to the system (if required).

6 Select the required mold setup.

7 Make sure that the mold setup is correct. Check the name and setpoints in the
preview window.

8 Correct any faults found during diagnostics.

9 Touch START to run the system.

10 Make sure that the controller is operates correctly. Monitor the Neo View or the
Text View screens.

NOTE: There are no controller-to-mold interconnection details included in this user guide. If
this information is required, please contact the nearest Husky Regional Service and
Sales office.

IMPORTANT!
When turning off the system, wait 30 seconds before turning the main disconnect
switch back on. Turning the system off and on incorrectly may result in system
communication problems.

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3.4 Supply Voltage Screen

The Supply Voltage screen shows a graphical view of the phase pairs from the Supply
Configuration parameter selected in the System Setup screen (in the Voltage Settings area).
The selections are:
• Delta 3PH
• Wye 3PH+N
• Single Phase
• Integrated TX
On the Neo5 Home screen, select the Supply Voltage button to see the Supply Voltage
screen.

.
The Supply Voltage screen shows a graphic image of the type of configuration that has been
selected. The four supply configurations are shown in Figure 3-1, Figure 3-2, Figure 3-3, and
Figure 3-4.

Figure 3-1 Delta 3PH Supply Voltage Screen

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Figure 3-2 Wye 3PH+N Supply Voltage Screen

Figure 3-3 Single Phase Supply Voltage Screen

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Figure 3-4 Integrated TX Supply Voltage Screen

Table 3-1 shows how the zones are connected to the input power.

Table 3-1 Input Power Information

Item Description
Schematic The image is a visual representation of the supply configuration.

Zone # Shows what phase pair the zone is connected to.

Phase Pair Phase pair label associated with the supply configuration schematic.

Volts The voltage value for all the zones associated with a phase.

Amps The amperage value for all the zones associated with a phase.

NOTE: The amperage value displayed shows one decimal place for systems with ICC2 cards
installed and two decimal places for systems with ICC3 cards installed. Both voltage
and amperage values display “---” if the voltage and amperage is not calibrated for all
the zones associated with a particular phase. The amperage value also displays “---” if
all of the zones associated with a particular phase are XL or HL cards.
The supply configuration is selected on the System Setup screen. The supply voltage can be
wired in four different configurations.

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Chapter 4 Altanium Operator Interface

This chapter gives a brief overview of the functionality of the Neo5 operator interface.

4.1 General

The operator interface consists of a touch-sensitive display screen.

The Neo5 operator interface is a high-resolution color LCD covered by a transparent touch
screen. This display offers the advantages of high definition and a wide viewing angle, even
in poor lighting conditions.

WARNING!
Pinch Point Hazard – keep hands and fingers clear of the Neo5 touch monitor hinge
mechanism.

CAUTION!
Mechanical hazard – risk of equipment damage. Only use your finger to operate the
touch screen. Do not use a screwdriver, pen, or any other tool to touch the screen
because they may damage the touch screen.

Use the touch display to move from screen to screen, enter data, and operate the hot runner
system.

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4.2 Operator Interface — Screens and Buttons

4.2.1 Dialog Box — Accept/Cancel Buttons

At the bottom of each screen, where you have entered new data, touch to save new or
changed data.

If you want to close the dialog box (no changes) touch .

4.2.2 Home Screen

The Neo5 Home screen is the screen you use to navigate to all the other screens in the
system. The system screen selections on the Home screen are organized into four groups:
Zone Views, Temperature Management, Data Collection and Monitoring, and System
Configuration.

Figure 4-1 Altanium Neo5 Controller Home Screen

1. Controller Function Buttons 2. System Status Field 3. Navigation Buttons 4. System Screen
Selections 5. Alarm Buttons 6. System and User Management Buttons 7. Screen Header
8. Screen Footer

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4.2.2.1 Basic/Advanced Mode

The Altanium Neo5 has Basic and Advanced Operating mode functionality. The controller is
normally delivered in Basic Operating mode. Basic Operating mode hides many familiar
buttons and functionality on the controller screens when compared to the previous Neo
model. As a result, the controller's screens will look different after power on. Figure 4-2 shows
the Neo5 Home screen while in Basic Operating mode.

Figure 4-2 Neo5 Home Screen in Basic Operating Mode

To change to Advanced Operating mode, do the steps that follow:

1. Touch the System Setup button in the System Configuration group or in the top right
corner of the screen (shown in Figure 4-2).
The System Setup screen shows (refer to Figure 4-3).

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Figure 4-3 System Setup Screen in Basic Operating Mode

2. Touch the Use Advanced Functionality checkbox (shown in Figure 4-3), so the check
mark shows.
The hidden buttons and functionality will now show on the System Setup screen.
3. Touch the Home button at the top right corner of the screen.
The Neo5 Home screen now shows the buttons that were previously hidden (refer to
Figure 4-1).

4.2.3 Header and Footer

The home screen has a header

and a footer.

The same header and footer appear on all screens.

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4.2.3.1 Header — Controller Function Buttons

Table 4-1 describes the controller function buttons.

Table 4-1 Controller Function Buttons

Button Description
Stop
Removes the power from all the zones, regardless of system condition.

Start
Applies power to the zones that have a setpoint.

Standby
Places the system in standby. If a timer is active, the time remaining is
displayed in the system header.
NOTE: You cannot put the system in standby during the ART process.
Boost
Places the system in boost mode. If a timer is active, the time remaining is
displayed in the system header.
NOTE: You cannot put the system in boost mode during the ART process.

4.2.3.2 Header — System Status Indicators

Table 4-2 describes the system status indicators.

Table 4-2 System Status Indicators

Indicator Description
System Ready To Mold
When the system starts, this status bar shows the
progress as the mold zones heat to the At Temperature
setpoint. The status bar and label do not show after the
zones get to the At Temperature setpoint.

At Temperature:
• Flashes when the zones are heating up to the
setpoint temperature.
• Solid when all automatic zones are ‘At temperature’.
• Off when the controller is stopped.
• Shows that the temperature values are given as °C
or °F.

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Table 4-2 System Status Indicators (Continued)

Indicator Description
Company Name
Your company name is displayed.

System Mode
This field shows the Neo5’s current system mode. For a
description of each system mode, refer to Section 4.3.

System Timer
If applicable, this shows the time remaining on the timer.

4.2.3.3 Header — Navigation Buttons

Table 4-3 describes the navigation buttons.

Table 4-3 Navigation Buttons

Button Description
Back
Shows the previous screen (maximum of 10 screens back).

Forward
Moves to the last screen that was displayed (maximum of 10 screens
forward).

Home
Shows to the Home screen.

System Setup
Shows to the System Setup screen.

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4.2.3.4 Footer — Alarm Buttons

Table 4-4 describes the alarm buttons.

Table 4-4 Alarm Buttons

Silence Horn
Stops the audible alarm.

Alarm Reset
Changes an alarm from active to inactive.

Alarm Status
The time and a description of the highest priority
active alarm is displayed. If an alarm is active, the
triangle icon will change to red.

4.2.3.5 Footer — System and User Management Buttons

Table 4-5 describes the system and user management buttons.

Table 4-5 System and User Management Buttons

Log off/Log on
Shows the name of the current user who is logged in. Touch the button
to login or logout.

Language Selection
Shows the language screen.

Choose a language and then touch the button.

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Table 4-5 System and User Management Buttons (Continued)

Save Now
Opens a dialog window that lets you save a screen shot, report, or
process data on the internal hard drive. The saved file can be
transferred to a USB drive or network with the use of the Mold Setup
Info screen. Refer to Section 4.5.

Mold Setup Info

Shows the File Management screen to display the currently loaded
mold and related mold folder. The first word is the name of the mold
folder. The second word is the name of the mold setup file.

Shows the date and time. Touch this field to show the Set Date and
Time dialog boxes.

4.2.4 System Screen Selections — Zone Views

Table 4-6 describes the Zone Views buttons.

Table 4-6 Zone Views Buttons

Button Description
Neo View
The Neo View screen shows an icon for each temperature zone in the mold.
The icons give the zone temperature, temperature setpoint, power output
percentage, voltage, and other information.

Multi-Group View
The Multi Group View screen has the zones organized into groups and
allows individual control of each group.

Text View
The Text View screen shows textual information of zone data.

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4.2.5 System Screen Selections — Temperature Management

Table 4-7 describes the Temperature Management buttons.

Table 4-7 Temperature Management Buttons

Button Description
Quick Set
The Quick Set screen is used to create and name groups of zones, set
temperatures and limits by zone, and many other configurations.

Staging
You can heat or cool zones in a selected order with the use of stages. Use
the Staging screen to assign zones to stages, set stage setpoints, and enter
soak timers for each stage.

Mold Test
Use the Mold Test screen to troubleshoot problems with a mold. You can
test the wiring integrity of a mold after maintenance has been done and
analyze the thermal isolation between all the cavities in the mold.

Mold Test Results

Use the Mold Test Results screen to examine the results of the diagnostic
tests.

4.2.6 System Screen Selections — Data Collection and Monitoring

Table 4-8 describes the Data Collection and Monitoring buttons.

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Table 4-8 Data Collection and Monitoring Buttons

Button Description
Alarms
Use the Alarms screen to see all errors that occur.

Event History
Use the Event History screen to see past alarms, warnings, setpoint
changes, setup changes, HMI startup, and operational events that do not
agree with specified conditions.

Data Exchange
Use the Data Exchange screen to select and save different report types to
the local drive, USB drive, or a network. You can save process data to those
same locations and enter the frequency in which the data is saved.

Power Deviation
Use the Power Deviation screen to see the zones with their heater types,
status, tolerance, and deviation. You can also select to see troubleshooting
data.

Supply Voltage
The Supply Voltage screen shows a graphical view of the phase pairs from
the Supply Configuration parameter selected in the System Setup screen:
• Delta 3PH
• Wye 3PH+N
• Single Phase
• Integrated TX
Zone numbers are listed with their phase pairs, voltages, and amperage.

Can Info
The Controller Area Network (CAN) Info screen is used for troubleshooting
communication issues on the CAN bus.

Process Monitor
Use the Process Monitoring screen to see zone graphical plots for:
• Setpoint
• Temperature
• Power
• Amps
• Leakage
• Volts

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4.2.7 System Screen Selections — System Configuration

Table 4-9 describes the System Configuration buttons.

Table 4-9 System Configuration Buttons

Button Description
System Setup
Use the System Setup screen to set some of the most commonly used
system wide preferences.

Zone Slot Config

Use the Zone Slot Config screen to identify the controller cards that
operate the zones. You can also set the amperage limits, thermocouple
type, select a card image, and enable the cards.

File Management
Use the File Management screen to store and work with files, such as mold
setups, images, documents, and reports.

Users
Human Machine Interface (HMI) administrators can use the Users screen to
create new users, change a user password, or delete a user.

Digital I/O
Use the Digital I/O screen to set the Neo5 inputs and outputs.

Zone Calibration
Use the Zone Calibration screen to calibrate the zones.

Customize
Use the Customize screen to configure what system functions and settings
are shown when in the Advanced and Basic Modes.

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4.3 System Modes

Table 4-10 gives the complete list and descriptions of the system modes that are shown in
the System Mode field of the screen header.

Table 4-10 System Modes

System Mode Description

Stop The system is stopped, and no power is being applied to the heaters.

Running The system is heating up to or maintaining the normal setpoint.

Manual Standby
The user pressed the Standby button and the system is heating to
the manual standby setpoint.

Remote Standby An external signal has activated the remote standby mode and the
system is heating up to the remote standby setpoint.

Delay Standby The system is delaying for a set period of time before entering the remote
standby mode.

Manual Boost
The user pressed the Boost button and the system is heating to
the boost setpoint.

Remote Boost An external signal has activated the remote boost mode and the system
is heating up to the remote boost setpoint.

Delay Boost The system is delaying for a set period of time before entering Remote
Boost mode.

Remote Stop With the remote stop input active, it prevents the user from starting the
system.

ART The Active Reasoning Technology (ART) tuning process is active.

Calibration The system allows the user to calibrate the thermocouple inputs for each
zone.

Diagnostics The mold diagnostics process is active.

Firmware Update A firmware update is in process on the selected control cards.

Bake Out Cycle 1 The system is baking out moisture in the mold. This is the first attempt.

Bake Out Cycle 2 The system is baking out moisture in the mold. This is the second
attempt.

Bake Out Cycle 3 The system is baking out moisture in the mold. This is the third attempt.

Bake Out Cycle 4 The system is baking out moisture in the mold. This is the fourth attempt.

Bake Out Cycle 5 The system is baking out moisture in the mold. This is the fifth attempt.

Soft Start The system is heating all zones up to setpoint in a gradual and even
manner.

Stage x Active (Heating) All zones assigned to stage x (1-4) are heating to the stage setpoint.

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Table 4-10 System Modes (Continued)

System Mode Description

Stage x Active (ART) The ART process is running on only the zones assigned to stage x.

Stage x Soaking After heating up, the system will maintain the stage x setpoint until the
(Heating) soak timer expires.

Stage x Active (Cooling) All zones assigned to stage x are cooling to the stage setpoint.

Stage x Soaking After cooling down, the system will maintain the stage x setpoint until
(Cooling) the soak timer expires.

Stage 4 Running The system will remain in stage 4 until the user presses the Start button
Indefinitely (Heating) to heat the zones to the normal setpoint.

Circuit Test The system makes sure that there are no heater circuit faults (open circuit,
short circuit, leakage, or wrong heater) on any zones.

4.4 Screen Keyboards, Keypads, and Selection Menus

The Neo5 controller uses screen keyboards, keypads, and selection menus. Keyboards are
used to enter text, such as names for users, zones, and groups. Keypads are used to enter
numeric values for operation settings, such as temperatures, power, time, and percentages.
Selection menus are used to easily select an item in a drop-down list. Figure 4-4 shows a
typical keyboard, keypad, and selection menu. Their functions are identified in the title bars.

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Figure 4-4 Typical Keyboard, Keypad, and Selection Menu

4.4.1 Keypad Use

The screen keyboards and selection menus are easy to use. You type in text, or make a
selection, and then select the button to accept the entry.
The screen keypads are also easy to use, but specific features must be identified. Figure 4-5
shows an example of the keypad for the Temperature Setpoint. The keypad buttons and
indications are identified.

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Figure 4-5 Temperature Setpoint Keypad Example

4.4.1.1 Enter a Specified Setpoint Value

You can enter a specific value for a setpoint. To do this, type the numbered value on the
screen keypad, and then select the button to accept the change.

4.4.1.2 Increase or Decrease a Setpoint by a Specified Value

You can raise or lower an existing setpoint by a specified amount with the use of the arrow
buttons at the bottom of the screen keypad.
The up-arrow button increases the existing setpoint by the value typed in the entry field. In
the Figure 4-5 example, the existing setpoint will increase by 10° when the up arrow is
selected.
The number below the arrow is the maximum numerical value that can be input in the dialog
window without exceeding the maximum limit of the setpoint.
NOTE: A maximum setpoint limit must be entered (refer to Section 8.7.4) before this button
becomes active.
The down arrow button decreases the exiting setpoint by the value typed in the entry field.
In the Figure 4-5 example, the existing setpoint will decrease by 10° when the up arrow is
selected.
The number below the arrow is the maximum numerical value that can be input in the dialog
window without going below the minimum limit of the setpoint.
NOTE: A minimum setpoint limit must be entered (refer to Section 8.7.4) before this button
becomes active.

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Example
To add or subtract a specified value from the existing zone temperature setpoint, do the
steps that follow:
1. Touch the box to the right of the Temperature Setpoint field. The Normal Temperature
Setpoint keypad shows.
NOTE: The two arrow buttons are at first grayed out.
2. Use the numbered keypad to type in the amount that you want to add or subtract from
the current setpoint.
NOTE: In the example shown in Figure 4-5, 10° has been typed in the entry field.
After you type the amount, the arrow buttons will become active (not grayed out).
3. Do one of the steps that follow:
a. To increase the existing setpoint, touch the up-arrow button and 10° will be added
to the setpoint.
You are returned to the Quick Set screen, and the setpoint shown in the selected
zone will increase by 10°.
b. To decrease the existing setpoint, touch the down arrow button and 10° will be
subtracted from the setpoint.
You are returned to the Quick Set screen, and the setpoint shown in the selected
zone will decrease by 10°.

4.5 Save Now

With the use of the Save Now button, you can save the files that follow to the system’s
internal hard drive:
• Screen shot
• Report list
• Process data
These files can then be transferred from the internal drive to a USB drive (plugged in to the
USB port) or to a network directory. The Save Now button is shown on all screens.
To use the Save Now feature, do the steps that follow:
1. Select the Save Now button near the bottom right corner of the screen.

The Save Now dialog shows (refer to Figure 4-6).

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Figure 4-6 Save Now Dialog

2. Touch the button next to the file(s) that you want saved.

The Save Files Result dialog shows.

Figure 4-7 Save Files Result Dialog

3. Touch the button to close the result dialog.

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4.6 Save a Dialog Window

You may find it necessary to save a screen shot of a dialog window. To do this, select the
camera button that is at the top right corner of all dialog windows.

A dialog shows to let you know that the file was saved successfully.

Touch the button to close the dialog.

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Chapter 5 Security and Administration

This chapter describes the user management functions.

5.1 Log In/Log Out

Users of the Neo5 controller must log into the system. Each user must have their own user
name and password. Do the steps that follow to log into the system:
To log in:
1. In the footer, touch the Log In/Log Out button.

2. Use the keyboard to type in your user name, then touch the button to continue
(refer to Figure 5-1).

Figure 5-1 User Name Dialog Screen

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3. Type in your password, then touch the button to complete the login (refer to
Figure 5-2).

Figure 5-2 Password Dialog Screen

To log out:
1. In the footer, touch the Log In/Log Out button.

The Logout dialog shows (refer to Figure 5-3).

Figure 5-3 Logout Dialog Screen

2. On the log out dialog window, touch the Log Out button to log out of the system.
You can touch the New Log In button to log in a new user.

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5.2 User Management and Security Screens

A user type is given to each person who operates the Neo5 (refer to Table 5-1). The user types
control what level of operations and changes are permitted, and what screens can be viewed
by the user in the Neo5 system.

Table 5-1 User Types

Role Definition
Guest (Default User) Can only look at screens and is not permitted to change setpoints.

Operator Can change screen data as permitted by Administrator.

Supervisor Can change screen data, with added user access to specified
screens as permitted by Administrator.

Administrator The same change control and access permitted to the Supervisor,
with the added control to create, delete, rename, and give all user
types.

From the Users screen, the administrator can add or delete a user or change a user’s
password. The administrator also controls security settings. The security settings allow or
deny access to the different features of the Neo5.

5.2.1 Manage Users

To create/delete a user or change a user’s password, do the steps that follow:

1. On the Neo5 Home screen, in the System Configuration group, select the Users button.

2. On the top of the Users screen, if necessary, select the User Management checkbox.

The Users screen shows (refer to Figure 5-4).

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Figure 5-4 Users Screen

5.2.1.1 Add a User

To add a new user, do the steps that follow:
1. Select the Add New User button at the left side of the screen.

2. Use the keyboard or drop-down selection dialogs to enter in the data that follows:
NOTE: The keyboard, keypad, and selection screens will automatically change to next
data screen after you select the button. Select the X button to cancel the
addition of the new user.
a. Type the user name and then select the button (refer to Figure 5-5).
NOTE: This is the user name that the user will enter to log in.

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Figure 5-5 User Name Keyboard

b. Type the user’s full name and then select the button (refer to Figure 5-5).

Figure 5-6 User’s Full Name Keyboard

c. Select the user role and then select the button (refer to Figure 5-7).

Figure 5-7 User Role Selection

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d. Type the password that the user must use and then select the button (refer to
Figure 5-8).

Figure 5-8 Password Keyboard

e. Type the password again to confirm it was entered correctly and then select the
button (refer to Figure 5-9)

Figure 5-9 Confirm Password Keyboard

f. Select a language for the user and then select the button (refer to Figure 5-10).

Figure 5-10 Language Selection

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g. Select the units (Imperial or Metric) for the user and then select the button
(refer to Figure 5-11).

Figure 5-11 Units Selection

h. Select the functionality (Advanced or Basic) for the user and then select the
button (refer to Figure 5-12). For more information about Advanced and Basic
functionality, refer to Chapter 6.

NOTE: Advanced gives the user access to more advanced settings.

Figure 5-12 Functionality Selection

i. Type the auto log out time and then select the button (refer to Figure 5-13).
When there is no activity for the time entered in the Auto Logout keypad, the Neo5
will automatically log out the user. The default time is 5 minutes. The minimum is 10
seconds.

Figure 5-13 Auto Log Out Time Keypad

After you have entered the auto log out time, the User Management screen will show and the
new user will be included with the list of other users.

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5.2.1.2 Delete a User

To delete a user, do the steps that follow:
1. Select the user in the User Name column as shown in Figure 5-14.

Figure 5-14 Select User to be Delete

2. Select the Delete User button at the left side of the screen.

The confirmation dialog shows (refer to Figure 5-15).

Figure 5-15 Delete User Confirmation

3. Select the button to complete the deletion.

The user is deleted.

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5.2.1.3 Change a User Password

To change a user password, do the steps that follow:
1. Select the user in the User Name column (refer to Figure 5-16).

Figure 5-16 Select the User for a Password Change

2. Select the Change Password button at the left side of the screen.

3. Type the user’s new password and then select the button (refer to Figure 5-17).

Figure 5-17 Password Keyboard

4. Type the password again to confirm it was entered correctly and then select the
button (refer to Figure 5-18)

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Figure 5-18 Confirm Password Keyboard

The password has changed.

5.2.2 Set the Security Settings

Security parameters can be set for each screen that has restrictions. When you touch a screen
name, it expands to show the list of parameters for that screen. Individual security levels are
available for the following:
• Adjustable parameters
• User commands, such as Standby and Boost
• Screen availability
To set security parameters for the Neo5 screens, do the steps that follow:

1. On the Neo5 Home screen, in the System Configuration group, select the Users button.

2. On the top of the Users screen, if necessary, select the User Management checkbox.

The Screen Security screen shows (refer to Figure 5-19).

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Figure 5-19 Screen Security Screen

3. On the Screen Security screen, assign a role (Operator, Supervisor or Administrator) to

each function.
• When Operator is selected, the supervisor and administrator roles also have access
to the function/screen.
• When Supervisor is selected, the operator cannot access that function/screen.
• When Administrator is selected, the supervisor and operator cannot access that
function/screen.
a. Touch a name tab that is next to an arrow to open the drop-down menu.
As an example, Figure 5-20 shows the drop-down list for File Management.

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Figure 5-20 Screen Security Drop-Down Selections

b. Touch the box to the right of a function/screen name in the list to show the Operator
Level selection dialog (Figure 5-21).

Figure 5-21 Operator Level Selection Dialog

c. Select the role for the function/screen and then select the button.
d. Continue to assign a user role for each function/screen for all of the tabs that remain
on the Screen Security screen.

NOTE: The Users tab is greyed out because only the administrator can manage users. Refer
to Section 5.2.1.

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5.2.3 Security Assignments Override

You can set an override for some of the functions/screens that already have their user roles
assigned. Touch the white box in a name tab and select the Operator Level that will override
the parameters under that tab.

5.2.4 Enable Security

You must put a check mark in the Enable Security box to apply all the security settings. The
default is Enable Security. You can touch the box and remove the check mark. This will
disable all the security settings and all users will have access to all functions/screens.

5.2.5 Security Settings List

Each screen on the Neo5 system is represented by a tab on the Screen Security screen. Touch
the tabs to see the available security restrictions for each system screen. The list that follows
shows the security settings found under each tab.
• All Screens
- Date and Time
- Start, Boost, Standby
- Silence Horn and Reset Alarms

• File Management (Override Capable)

- Create and load setups
- Save and discard changes
- Advanced file operations

• Event History (Override Capable)

- Change filter settings

• Multi-Group View
- Configure Group Order
- Modify Group Control
- Modify Group Color

• Power Deviation
- Configure Feature
- Relearn Baseline
- Access Troubleshooting Screen

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• System Setup (Override Capable)

- Monitor Zone Settings
- Wattage Voltage
- Global Output Power Limit
- Alarm Control Settings
- Show Thermocouple Readings
- Temperature Units
- At-Temperature Controls
- System Settings
- Force Phase Angle Control
- Earth Leakage Enable
- Earth Leakage Setup
- Bake Out Enable
- Bake Out Setup
- Supply Configuration
- Diagnostics Export
- Circuit Test Setup
- Heat Uniformity
- Auto Following Settings
- Soft Start to ART Setpoint Enable
- Customized Functionality
- Default Settings
- Same Sensor Input Max Limit
- Heat Sequencing
- Tuning
- Voltage Regulation

• Zone Slot Config (Override Capable)

- Zone/Slot Configuration

• Digital I/O
- Configure Digital I/O

• Staging
- Configuration

• Data Exchange
- Select Report Type
- Save to Local or USB Location
- Save to Network Location
- Save Process Data Setup
- Save Process Data As
- Setup Network Interface
- Setup Network Share
- Setup Time Synchronization
- OPC UA Interface Settings
- OPC UA Certificate Management

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• Quick Set
- Frequently Used
- Zone Edit
- Setpoint Limits
- Advanced Settings
- Control Settings
- Standby and Boost
- ART Settings
- No Heater Detected Enable
- Heater Types
- Groups

• Users (One Selection)

• Mold Test
- Configure and Run

• Zone Calibration
- Calibrate Zones
- Load Default Calibration

• Customize (One Selection)

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Chapter 6 Customize

The Customize screen is used to configure what system functions and settings are shown
when in the Advanced and Basic Modes. This screen is also where you can setup which screen
the controller shows when powered ON.
To see the Customize screen, select the Customize button in the System Configuration
group of the Neo5 Home screen.
NOTE: If the Customize button does not show on the Neo5 Home screen, refer to
Section 4.2.2.1.

The Customize screen shows (refer to Figure 6-1).

Figure 6-1 Customize Screen

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6.1 Customize Screen Buttons

Table 6-1 describes the buttons found on the Customize screen.

Table 6-1 Customize Screen Buttons

Button Description
Advanced Touch the Advanced radio button to display all settings and functionality
that can be assigned to Advanced Mode.

Basic Touch the Basic radio button to display all settings and functionality that
can be assigned to Basic Mode.

System Touch the System radio button to display the menu for selecting which
screen the system will show after booting up.

Reset to Default Touch the Reset to Default Values button to return all settings in the
Values Customize screen (Advanced, Basic and System) to factory defaults.

Function Settings Touch the Function Settings buttons to do what follows:

• If an arrow is shown, touch the button to expand a menu of setting
buttons related with that group. Touch the YES/NO field to the right
of the button label to show a dialog to hide (NO) or display (YES) that
button or function when the system is in the assigned mode.
Changes are applied to the mode (Advanced or Basic) that is selected
at the top of the Customize screen.
• If an arrow is not shown, touch the YES/NO field to the right of the
button label to show a dialog to hide (NO) or show (YES) that screen
when the system is in the assigned mode (Advanced or Basic).
Changes are applied to the mode (Advanced or Basic) that is selected
at the top of the Customize screen.

6.1.1 Advanced Setup Screen

The Advanced setup screen is used to configure what settings and functionality will be
available when a user is in Advanced mode. All changes made in this screen are automatically
saved and are applied whenever a user logs in with a user profile configured for Advanced
mode or the Use Advanced Functionality box is selected in the System Setup screen.

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Table 6-2 describes the Advanced Setup screen default settings. When an item setting is Yes,
the item is shown on the screen. If set to No, the item is not shown.

Table 6-2 Advanced Setup Default Settings

Default
Item Available Settings Description
Value
Screen History Yes Shows the Back and Forward buttons in the
System Header that are used to navigate
through the previous 10 screens viewed.
General
File Management Yes Shows the File Management button on the
Navigation Home screen and disables the Mold Setup Info
button in the system footer.

Language Yes Shows the Language Selection button in the

Selection system footer.

Neo View Neo View Yes Shows the Neo View button on the Home
screen.

Multi-Group Multi-Group View Yes Shows the Muti-Group View button on the
View Home screen.

Text View Text View Yes Shows the Text View button on the Home
screen.

Quick Set Quick Set Yes Shows the Quick Set button on the Home
screen.

QS - Frequently Yes Shows the entire Frequently Used menu in the

Used Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Frequently Used menu in the Quick Set screen.
QS - Frequently
Used Power Setpoint Yes Shows the Power Setpoint setting in the
Frequently Used menu in the Quick Set screen.
Zone On/Off Yes Shows the Zone On/Off setting in the
Frequently Used menu in the Quick Set screen.

Regulation Mode Yes Shows the Regulation Mode setting in the

Frequently Used menu in the Quick Set screen.

Alarm Window Yes Shows the Alarm Window setting in the

Frequently Used menu in the Quick Set screen.

Abort Window Yes Shows the Abort Window setting in the

Frequently Used menu in the Quick Set screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Zone Edit Yes Shows the entire Zone Edit menu in the Quick
Set screen.

QS - Zone Edit Zone Name Yes Shows the Zone Name setting in the Zone Edit
menu in the Quick Set screen.

Locked/Unlocked Yes Shows the Locked/Unlocked setting in the

Zone Edit menu in the Quick Set screen.
Display/Hide Yes Shows the Display/Hide setting in the Zone Edit
menu in the Quick Set screen.

QS - Groups Yes Shows the entire Groups menu in the Quick Set
screen.
QS - Groups
Group Yes Shows the Group assignment setting in the
Groups menu in the Quick Set screen.

Group 1 - 10 Name Yes Shows the Group 1 - 10 Name setting in the

Groups menu in the Quick Set screen

QS - Setpoint Limits Yes Shows the entire Setpoint Limits menu in the
Quick Set screen.

QS - Setpoint Temperature Yes Shows the Temperature Minimum setting in the

Limits Minimum Setpoint Limits menu in the Quick Set screen.

Temperature Yes Shows the Temperature Maximum setting in

Maximum the Setpoint Limits menu in the Quick Set
screen.

Power Minimum Yes Shows the Power Minimum setting in the

Setpoint Limits menu in the Quick Set screen.

Power Maximum Yes Shows the Power Maximum setting in the

Setpoint Limits menu in the Quick Set screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Manual Yes Shows the entire Manual Standby menu in the
Standby Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Manual Standby menu in the Quick Set screen.

Temperature Yes Shows the Temperature Minimum setting in the

QS - Manual
Minimum Manual Standby menu in the Quick Set screen.
Standby
Temperature Yes Shows the Temperature Maximum setting in
Maximum the Manual Standby menu in the Quick Set
screen.

Power Setpoint Yes Shows the Power Setpoint setting in the Manual
Standby menu in the Quick Set screen.

Power Minimum Yes Shows the Power Minimum setting in the

Manual Standby menu in the Quick Set screen.

Power Maximum Yes Shows the Power Maximum setting in the

Manual Standby menu in the Quick Set screen.

Duration Timer Yes Shows the Duration Timer setting in the Manual
Standby menu in the Quick Set screen.

QS - Manual Boost Yes Shows the entire Manual Boost menu in the
Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Manual Boost menu in the Quick Set screen.

Temperature Yes Shows the Temperature Minimum setting in the

QS - Manual
Minimum Manual Boost menu in the Quick Set screen.
Boost
Temperature Yes Shows the Temperature Maximum setting in
Maximum the Manual Boost menu in the Quick Set screen.

Power Setpoint Yes Shows the Power Setpoint setting in the Manual
Boost menu in the Quick Set screen.

Power Minimum Yes Shows the Power Minimum setting in the

Manual Boost menu in the Quick Set screen.

Power Maximum Yes Shows the Power Maximum setting in the

Manual Boost menu in the Quick Set screen.

Duration Timer Yes Shows the Duration Timer setting in the Manual
Boost menu in the Quick Set screen

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Remote Yes Shows the entire Remote Standby menu in the
Standby Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Remote Standby menu in the Quick Set screen.

Temperature Yes Shows the Temperature Minimum setting in the

Minimum Remote Standby menu in the Quick Set screen.

Temperature Yes Shows the Temperature Maximum setting in

QS - Remote Maximum the Remote Standby menu in the Quick Set
Standby screen.

Power Setpoint Yes Shows the Power Setpoint setting in the

Remote Standby menu in the Quick Set screen.

Power Minimum Yes Shows the Power Minimum setting in the

Remote Standby menu in the Quick Set screen.

Power Maximum Yes Shows the Power Maximum setting in the

Remote Standby menu in the Quick Set screen.

Duration Yes Shows the Duration setting in the Remote

Standby menu in the Quick Set screen.

Delay Yes Shows the Delay setting in the Remote Standby

menu in the Quick Set screen.

Input Mode Yes Shows the Input Mode n setting in the Remote
Standby menu in the Quick Set screen.

Reset Delay Timer Yes Shows the Reset Delay Timer in Direct Mode
in Direct Mode setting in the Remote Standby menu in the
Quick Set screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Remote Boost Yes Shows the entire Remote Boost menu in the
Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Remote Boost menu in the Quick Set screen.

Temperature Yes Shows the Temperature Minimum setting in the

Minimum Remote Boost menu in the Quick Set screen.

Temperature Yes Shows the Temperature Maximum setting in

QS - Remote Maximum the Remote Boost menu in the Quick Set screen.
Boost
Power Setpoint Yes Shows the Power Setpoint setting in the
Remote Boost menu in the Quick Set screen.

Power Minimum Yes Shows the Power Minimum setting in the

Remote Boost menu in the Quick Set screen.

Power Maximum Yes Shows the Power Maximum setting in the

Remote Boost menu in the Quick Set screen.

Duration Yes Shows the Duration setting in the Remote Boost

menu in the Quick Set screen.

Delay Yes Shows the Delay setting in the Remote Boost

menu in the Quick Set screen.

Input Mode Yes Shows the Input Mode n setting in the Remote
Boost menu in the Quick Set screen.

QS - Heater Types Yes Shows the entire Heater Types menu in the
Quick Set screen.
QS - Heater
Types Heater Type Yes Shows the Heater Type assignment setting in
the Heater Types menu in the Quick Set screen.
Custom Type 1 - 8 Yes Shows the Custom Type 1 - 8 settings in the
Heater Types menu in the Quick Set screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Advanced Yes Shows the entire Advanced Settings menu in
Settings the Quick Set screen.

Output Power Yes Shows the Output Power Limit setting in the
Limit Advanced Settings menu in the Quick Set
screen.

Assigned Leader Yes Shows the Assigned Leader Zone setting in the
Zone Advanced Settings menu in the Quick Set
screen.

QS - Advanced Sensor Input Yes Shows the Sensor Input setting in the Advanced
Settings Settings menu in the Quick Set screen.

Output Mode Yes Shows the Output Mode setting in the

Advanced Settings menu in the Quick Set
screen.

PCM - Priority Yes Shows the PCM setting in the Advanced

Control Mode Settings menu in the Quick Set screen.

AMC Yes Shows the AMC setting in the Advanced

Settings menu in the Quick Set screen.

Earth Leakage Yes Shows the Earth Leakage Check setting in the
Check Advanced Settings menu in the Quick Set
screen.

Earth Leakage Yes Shows the Earth Leakage Limit setting in the
Limit Advanced Settings menu in the Quick Set
screen.

No Response Limit Yes Shows the No Response Limit setting in the

Advanced Settings menu in the Quick Set
screen.

No Heater Yes Shows the No Heater Detected Enabled setting

Detected Enabled in the Advanced Settings menu in the Quick Set
screen.

No Heater Limit Yes Shows the No Heater Limit setting in the

Advanced Settings menu in the Quick Set
screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Control Yes Shows the entire Control Settings menu in the
Settings Quick Set screen.

Control Mode Yes Shows the Control Mode setting in the Control
Settings menu in the Quick Set screen.
QS - Control
Settings P - Proportional Yes Shows the Proportional setting in the Control
Settings menu in the Quick Set screen.

I - Integral Yes Shows the Integral setting in the Control

Settings menu in the Quick Set screen.

D - Derivative Yes Shows the Derivative setting in the Control

Settings menu in the Quick Set screen.

P - ART Yes Shows the Proportional - ART setting in the

Control Settings menu in the Quick Set screen.

I - ART Yes Shows the Integral - ART setting in the Control

Settings menu in the Quick Set screen.

D - ART Yes Shows the Derivative - ART setting in the

Control Settings menu in the Quick Set screen.

QS - ART Settings Yes Shows the entire ART Settings menu in the
Quick Set screen.

ART Yes Shows the ART setting in the ART Settings menu
in the Quick Set screen..

ART Values Yes Shows the ART Values setting in the ART
QS - ART Settings
Settings menu in the Quick Set screen.

Output Gain Yes Shows the Output Gain setting in the ART
Settings menu in the Quick Set screen.

Minimum P Yes Shows the Minimum P setting in the ART

Settings menu in the Quick Set screen.

Minimum I Yes Shows the Minimum I setting in the ART

Settings menu in the Quick Set screen.

Minimum D Yes Shows the Minimum D setting in the ART

Settings menu in the Quick Set screen.

Default P Yes Shows the Default P setting in the ART Settings

menu in the Quick Set screen.

Default I Yes Shows the Default I setting in the ART Settings

menu in the Quick Set screen.

Default D Yes Shows the Default D setting in the ART Settings

menu in the Quick Set screen.

ART Offset Yes Shows the ART Offset setting in the ART
Settings menu in the Quick Set screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
Staging Staging Yes Shows the Staging button on the Home screen.

Mold Test Mold Test Yes Shows the Mold Test button on the Home
screen.

Mold Test Results Yes Shows the Mold Test Results button on the
Home screen and the Mold Test screen.
Mold Test
Results Test Comparison Yes Shows the Compare check box, the Save Test
button and Delete Test button in the Mold Test
Results screen.

Change Tolerances Yes Shows the Change Tolerances button in the

Mold Test Results screen.

Event History Event History Yes Shows the Event History button on the Home
screen.

Events Filter Yes Shows the Events Filter button in the Event
History screen.

Data Exchange Data Exchange Yes Shows the Data Exchange button on the Home
screen.

Power Deviation Power Deviation Yes Shows the Power Deviation button on the
Home screen.

Supply Voltage Supply Voltage Yes Shows the Supply Voltage button on the Home
screen.

Can Info Can Info Yes Shows the Can Info button on the Home screen.

Process Monitor Process Monitor Yes Shows the Process Monitor button on the Home
screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
Auto Save Mold No Selects the Auto Save Mold Setup feature for
Setup use.

Monitor Zone Yes Shows the Monitor Zone Settings panel.

Settings

Mold Settings Yes Shows the Mold Settings panel.

Voltage Settings Yes Shows the Voltage Settings panel.

Diagnostics Export Yes Shows the Diagnostics Export panel.

System Setup Open Source Yes Shows the Open Source Software panel.
Software

Zone Alarm Yes Shows the Zone Alarm Control panel.

Control

Heat Uniformity Yes Shows the Heat Uniformity panel.

At Temperature Yes Shows the At Temperature panel.

Auto Following Yes Shows the Auto Following panel.

Options and Yes Shows the Options and Licensing panel.

Licensing

Earth Leakage Yes Shows the Earth Leakage panel.

Circuit Test Yes Shows the Circuit Test panel.

Bake Out Yes Shows the Bake Out panel.

Zone Slot Config Zone Slot Config Yes Shows the Zone Slot Config button on the
Home screen.

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Table 6-2 Advanced Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
File Management Yes Shows the File Management button on the
Home screen and disables the File Management
navigation button in the system footer.

File Type Filter Yes Shows the radio buttons in the File Type Filter
group.

Setup Changes Yes Shows the buttons in the Setup Changes group.

File Directory Yes Shows the buttons in the File Directory group.
File
Management Remote Location Yes Shows the Remote Location radio buttons.

New Mold Yes Shows the New Mold button.

Operation

New Setup Yes Shows the New Setup button.

Operation

Load Operation Yes Shows the Load button.

Save As Operation Yes Shows the Save As button.

Copy Operation Yes Shows the Copy button.

Delete Operation Yes Shows the Delete button.

Rename Operation Yes Shows the Rename button.

Preview Operation Yes Shows the Preview button.

Users Yes Shows the Users button on the Home screen.

Users User Management Yes Shows the User Management radio button.

Screen Security Yes Shows the Screen Security radio button.

Digital I/O Digital I/O Yes Shows the Digital I/O button on the Home
screen.

Zone Calibration Zone Calibration Yes Shows the Zone Calibration button on the
Home screen.

Customize Customize Yes Shows the Customize button on the Home

screen.

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6.2 Basic Setup Screen

The Basic setup screen is used to configure what settings and functionality will be available
when a user is in Basic mode. All changes made in this screen are automatically saved and are
applied whenever a user logs in with a user profile configured for Basic mode or the Use
Advanced Functionality box is deselected in the System Setup screen.
Table 6-3 describes the Basic Setup screen default settings. When an item setting is Yes, the
item is shown on the screen. If set to No, the item is not shown.

Table 6-3 Basic Setup Default Settings

Default
Item Available Settings Description
Value
Screen History No Shows the Back and Forward buttons in the
System Header that are used to navigate
through the previous screen 10 screens viewed.
General
File Management Yes Shows the File Management button on the
Navigation Home screen and disables the Mold Setup Info
button in the system footer.

Language No Shows the Language Selection button in the

Selection system footer.

Neo View Neo View Yes Shows the Neo View button on the Home
screen.

Multi-Group Multi-Group View No Shows the Muti-Group View button on the

View Home screen.

Text View Text View No Shows the Text View button on the Home
screen.

Quick Set Quick Set No Shows the Quick Set button on the Home
screen.

QS - Frequently Yes Shows the entire Frequently Used menu in the

Used Quick Set screen.

Temperature Yes Shows the Temperature Setpoint setting in the

Setpoint Frequently Used menu in the Quick Set screen.
QS - Frequently
Used Power Setpoint Yes Shows the Power Setpoint setting in the
Frequently Used menu in the Quick Set screen.

Zone On/Off Yes Shows the Zone On/Off setting in the

Frequently Used menu in the Quick Set screen.

Regulation Mode Yes Shows the Regulation Mode setting in the

Frequently Used menu in the Quick Set screen.

Alarm Window Yes Shows the Alarm Window setting in the

Frequently Used menu in the Quick Set screen.

Abort Window Yes Shows the Abort Window setting in the

Frequently Used menu in the Quick Set screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Zone Edit No Shows the entire Zone Edit menu in the Quick
Set screen.

QS - Zone Edit Zone Name No Shows the Zone Name setting in the Zone Edit
menu in the Quick Set screen.

Locked/Unlocked No Shows the Locked/Unlocked setting in the

Zone Edit menu in the Quick Set screen.
Display/Hide No Shows the Display/Hide setting in the Zone Edit
menu in the Quick Set screen.

QS - Groups No Shows the entire Groups menu in the Quick Set

screen.
QS - Groups
Group No Shows the Group assignment setting in the
Groups menu in the Quick Set screen.

Group 1 - 10 Name No Shows the Group 1 - 10 Name setting in the

Groups menu in the Quick Set screen

QS - Setpoint Limits No Shows the entire Setpoint Limits menu in the

Quick Set screen.

QS - Setpoint Temperature No Shows the Temperature Minimum setting in the

Limits Minimum Setpoint Limits menu in the Quick Set screen.

Temperature No Shows the Temperature Maximum setting in

Maximum the Setpoint Limits menu in the Quick Set
screen.

Power Minimum No Shows the Power Minimum setting in the

Setpoint Limits menu in the Quick Set screen.

Power Maximum No Shows the Power Maximum setting in the

Setpoint Limits menu in the Quick Set screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Manual No Shows the entire Manual Standby menu in the
Standby Quick Set screen.

Temperature No Shows the Temperature Setpoint setting in the

Setpoint Manual Standby menu in the Quick Set screen.

Temperature No Shows the Temperature Minimum setting in the

QS - Manual
Minimum Manual Standby menu in the Quick Set screen.
Standby
Temperature No Shows the Temperature Maximum setting in
Maximum the Manual Standby menu in the Quick Set
screen.

Power Setpoint No Shows the Power Setpoint setting in the Manual

Standby menu in the Quick Set screen.

Power Minimum No Shows the Power Minimum setting in the

Manual Standby menu in the Quick Set screen.

Power Maximum No Shows the Power Maximum setting in the

Manual Standby menu in the Quick Set screen.

Duration Timer No Shows the Duration Timer setting in the Manual

Standby menu in the Quick Set screen.

QS - Manual Boost No Shows the entire Manual Boost menu in the

Quick Set screen.

Temperature No Shows the Temperature Setpoint setting in the

Setpoint Manual Boost menu in the Quick Set screen.

Temperature No Shows the Temperature Minimum setting in the

QS - Manual
Minimum Manual Boost menu in the Quick Set screen.
Boost
Temperature No Shows the Temperature Maximum setting in
Maximum the Manual Boost menu in the Quick Set screen.

Power Setpoint No Shows the Power Setpoint setting in the Manual

Boost menu in the Quick Set screen.

Power Minimum No Shows the Power Minimum setting in the

Manual Boost menu in the Quick Set screen.

Power Maximum No Shows the Power Maximum setting in the

Manual Boost menu in the Quick Set screen.

Duration Timer No Shows the Duration Timer setting in the Manual

Boost menu in the Quick Set screen

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Remote No Shows the entire Remote Standby menu in the
Standby Quick Set screen.

Temperature No Shows the Temperature Setpoint setting in the

Setpoint Remote Standby menu in the Quick Set screen.

Temperature No Shows the Temperature Minimum setting in the

Minimum Remote Standby menu in the Quick Set screen.

Temperature No Shows the Temperature Maximum setting in

QS - Remote Maximum the Remote Standby menu in the Quick Set
Standby screen.

Power Setpoint No Shows the Power Setpoint setting in the

Remote Standby menu in the Quick Set screen.

Power Minimum No Shows the Power Minimum setting in the

Remote Standby menu in the Quick Set screen.

Power Maximum No Shows the Power Maximum setting in the

Remote Standby menu in the Quick Set screen.

Duration No Shows the Duration setting in the Remote

Standby menu in the Quick Set screen.

Delay No Shows the Delay setting in the Remote Standby

menu in the Quick Set screen.

Input Mode No Shows the Input Mode n setting in the Remote

Standby menu in the Quick Set screen.

Reset Delay Timer No Shows the Reset Delay Timer in Direct Mode
in Direct Mode setting in the Remote Standby menu in the
Quick Set screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Remote Boost No Shows the entire Remote Boost menu in the
Quick Set screen.

Temperature No Shows the Temperature Setpoint setting in the

Setpoint Remote Boost menu in the Quick Set screen.

Temperature No Shows the Temperature Minimum setting in the

Minimum Remote Boost menu in the Quick Set screen.

Temperature No Shows the Temperature Maximum setting in

QS - Remote Maximum the Remote Boost menu in the Quick Set screen.
Boost
Power Setpoint No Shows the Power Setpoint setting in the
Remote Boost menu in the Quick Set screen.

Power Minimum No Shows the Power Minimum setting in the

Remote Boost menu in the Quick Set screen.

Power Maximum No Shows the Power Maximum setting in the

Remote Boost menu in the Quick Set screen.

Duration No Shows the Duration setting in the Remote Boost

menu in the Quick Set screen.

Delay No Shows the Delay setting in the Remote Boost

menu in the Quick Set screen.

Input Mode No Shows the Input Mode n setting in the Remote

Boost menu in the Quick Set screen.

QS - Heater Types No Shows the entire Heater Types menu in the

Quick Set screen.
QS - Heater
Types Heater Type No Shows the Heater Type assignment setting in
the Heater Types menu in the Quick Set screen.
Custom Type 1 - 8 No Shows the Custom Type 1 - 8 settings in the
Heater Types menu in the Quick Set screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Advanced No Shows the entire Advanced Settings menu in
Settings the Quick Set screen.

Output Power No Shows the Output Power Limit setting in the

Limit Advanced Settings menu in the Quick Set
screen.

Assigned Leader No Shows the Assigned Leader Zone setting in the

Zone Advanced Settings menu in the Quick Set
screen.

QS - Advanced Sensor Input No Shows the Sensor Input setting in the Advanced
Settings Settings menu in the Quick Set screen.

Output Mode No Shows the Output Mode setting in the

Advanced Settings menu in the Quick Set
screen.

PCM - Priority No Shows the PCM setting in the Advanced

Control Mode Settings menu in the Quick Set screen.

AMC No Shows the AMC setting in the Advanced

Settings menu in the Quick Set screen.

Earth Leakage No Shows the Earth Leakage Check setting in the

Check Advanced Settings menu in the Quick Set
screen.

Earth Leakage No Shows the Earth Leakage Limit setting in the

Limit Advanced Settings menu in the Quick Set
screen.

No Response Limit No Shows the No Response Limit setting in the

Advanced Settings menu in the Quick Set
screen.

No Heater No Shows the No Heater Detected Enabled setting

Detected Enabled in the Advanced Settings menu in the Quick Set
screen.

No Heater Limit No Shows the No Heater Limit setting in the

Advanced Settings menu in the Quick Set
screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
QS - Control No Shows the entire Control Settings menu in the
Settings Quick Set screen.

Control Mode No Shows the Control Mode setting in the Control

Settings menu in the Quick Set screen.
QS - Control
Settings P - Proportional No Shows the Proportional setting in the Control
Settings menu in the Quick Set screen.

I - Integral No Shows the Integral setting in the Control

Settings menu in the Quick Set screen.

D - Derivative No Shows the Derivative setting in the Control

Settings menu in the Quick Set screen.

P - ART No Shows the Proportional - ART setting in the

Control Settings menu in the Quick Set screen.

I - ART No Shows the Integral - ART setting in the Control

Settings menu in the Quick Set screen.

D - ART No Shows the Derivative - ART setting in the

Control Settings menu in the Quick Set screen.

QS - ART Settings No Shows the entire ART Settings menu in the

Quick Set screen.

ART No Shows the ART setting in the ART Settings menu

in the Quick Set screen.

ART Values No Shows the ART Values setting in the ART

QS - ART Settings
Settings menu in the Quick Set screen.

Output Gain No Shows the Output Gain setting in the ART

Settings menu in the Quick Set screen.

Minimum P No Shows the Minimum P setting in the ART

Settings menu in the Quick Set screen.

Minimum I No Shows the Minimum I setting in the ART

Settings menu in the Quick Set screen.

Minimum D No Shows the Minimum D setting in the ART

Settings menu in the Quick Set screen.

Default P No Shows the Default P setting in the ART Settings

menu in the Quick Set screen.

Default I No Shows the Default I setting in the ART Settings

menu in the Quick Set screen.

Default D No Shows the Default D setting in the ART Settings

menu in the Quick Set screen.

ART Offset No Shows the ART Offset setting in the ART

Settings menu in the Quick Set screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
Staging Staging No Shows the Staging button on the Home screen.

Mold Test Mold Test No Shows the Mold Test button on the Home
screen.

Mold Test Results No Shows the Mold Test Results button on the
Home screen and the Mold Test screen.
Mold Test
Results Test Comparison No Shows the Compare check box, the Save Test
button and Delete Test button in the Mold Test
Results screen.

Change Tolerances No Shows the Change Tolerances button in the

Mold Test Results screen.

Event History Event History No Shows the Event History button on the Home
screen.

Events Filter No Shows the Events Filter button in the Event

History screen.

Data Exchange Data Exchange No Shows the Data Exchange button on the Home
screen.

Power Deviation Power Deviation No Shows the Power Deviation button on the
Home screen.

Supply Voltage Supply Voltage No Shows the Supply Voltage button on the Home
screen.

Can Info Can Info No Shows the Can Info button on the Home screen.

Process Monitor Process Monitor No Shows the Process Monitor button on the Home
screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
Auto Save Mold Yes Selects the Auto Save Mold Setup feature for
Setup use.

Monitor Zone No Shows the Monitor Zone Settings panel.

Settings

Mold Settings No Shows the Mold Settings panel.

Voltage Settings No Shows the Voltage Settings panel.

Diagnostics Export No Shows the Diagnostics Export panel.

System Setup Open Source No Shows the Open Source Software panel.
Software

Zone Alarm No Shows the Zone Alarm Control panel.

Control

Heat Uniformity No Shows the Heat Uniformity panel.

At Temperature No Shows the At Temperature panel.

Auto Following No Shows the Auto Following panel.

Options and No Shows the Options and Licensing panel.

Licensing

Earth Leakage No Shows the Earth Leakage panel.

Circuit Test No Shows the Circuit Test panel.

Bake Out No Shows the Bake Out panel.

Zone Slot Config Zone Slot Config No Shows the Zone Slot Config button on the
Home screen.

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Table 6-3 Basic Setup Default Settings (Continued)

Default
Item Available Settings Description
Value
File Management No Shows the File Management button on the
Home screen and disables the File Management
navigation button in the system footer.

File Type Filter No Shows the radio buttons in the File Type Filter
group.

Setup Changes No Shows the buttons in the Setup Changes group.

File Directory No Shows the buttons in the File Directory group.

File
Management Remote Location No Shows the Remote Location radio buttons.

New Mold No Shows the New Mold button.

Operation

New Setup No Shows the New Setup button.

Operation

Load Operation No Shows the Load button.

Save As Operation No Shows the Save As button.

Copy Operation No Shows the Copy button.

Delete Operation No Shows the Delete button.

Rename Operation No Shows the Rename button.

Preview Operation No Shows the Preview button.

Users No Shows the Users button on the Home screen.

Users User Management No Shows the User Management radio button.

Screen Security No Shows the Screen Security radio button.

Digital I/O Digital I/O No Shows the Digital I/O button on the Home
screen.

Zone Calibration Zone Calibration No Shows the Zone Calibration button on the
Home screen.

Customize Customize No Shows the Customize button on the Home

screen.

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6.2.1 System Setup Screen

The System setup screen is used to configure what screen will be displayed after the
controller is powered ON. All changes made in this screen are automatically saved. The
choices are the Home, Neo View, Multi-Group View, or Text View screens.
Table 6-4 describes the System Setup screen default settings.

Table 6-4 System Setup Default Settings

Default
Item Available Settings Description
Value
Home No Forces the system to boot up to the Home
screen.
Boot Up to
Specific Screen Neo View Yes Forces the system to boot up to the Neo View
screen.

Multi-Group View No Forces the system to boot up to the Multi-

Group View screen.

Text View No Forces the system to boot up to the Text View

screen.

6.2.2 Import/Export Customize Screen Settings

The Neo5 has an Export and Import Settings function for transferring a file that contains the
Advanced mode, Basic mode, and System settings, configured in the Customize screen, to a
USB flash drive. This file can be imported to another Neo5 controller to simplify the
Customize screen setup.
The filename format is: Customize_[date]_[time].settings
Example: Customize_2021-01-01_09-30-00_settings
The sections that follow give instructions about the import and export of Customize screen
settings.

6.2.2.1 Export Customize Screen Settings

After you have set your Customize screen settings, do the steps the follow:
1. Insert a USB flash drive into the USB port on the Neo5 controller.
2. Select the System Setup button on the Neo5 Home screen or in the screen header.

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3. In the Customized Functionality area of the System Setup screen, select the Export
Settings button (refer to Figure 6-2).

Figure 6-2 Export Customize Screen Settings

A dialog window will show to say that the file was exported successfully.

4. Select the button to close the dialog.

5. Remove the USB drive from the USB port.

6.2.2.2 Import Customize Screen Settings

To import Customize screen settings, do the steps the follow:
1. Insert the USB flash drive with the Customize screen settings file into the USB port on the
Neo5 controller.
2. Select the System Setup button on the Neo5 Home screen or in the screen header.

3. In the Customized Functionality area of the System Setup screen, select the Import
Settings button (refer to Figure 6-3).

Figure 6-3 Import Customize Screen Settings

A dialog window will show that lists the saved Customize screen settings files on the USB
drive (refer to Figure 6-4).

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Figure 6-4 Select an Import File

4. Select the file that you want to import and then select the button to close the
dialog.
A dialog window will show to say that the settings were imported successfully.

5. Select the button to close the dialog.

6. Remove the USB drive from the USB port.

6.2.3 Assign Advanced or Basic Mode to a User Profile

The Advanced or Basic mode can be assigned to an individual user profile. This is done in the
User Management section of the Users screen. After a mode has been assigned to a user
profile, the controller will automatically switch to the assigned mode when the user logs
onto the system.
NOTE: You must have the appropriate user role to do this action.

6.2.3.1 Assign a Mode to a User Profile

To assign a mode to a user profile, do the steps that follow:

NOTE: If this is for a new user, do the steps in Section 5.2.1.1 to add the new user.
1. From the Neo5 Home screen, select the Users button.

2. On the Users screen, select the User Management radio button.

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3. In the user’s row on the User Management screen, select the cell in the Functionality
column for that user, so the cell is highlighted.

4. Touch the Edit button in the left side of the User Management screen.

5. Select Advanced or Basic from the Functionality dialog window, and then select the
button to accept the selection.

6.3 Default Screen Settings

The Default Settings screen is used to modify the factory default settings that are assigned to
a new mold setup file.
To see the Default Setup screen, do the steps that follow:
1. Select the File Management button on the Neo5 Home screen or in the screen footer.

2. In the Setup Changes area of the File Management screen (top middle of the screen),
select the Default Setup button.

The Default Settings screen shows (refer to Figure 6-5).

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Figure 6-5 Default Settings Screen

6.3.1 Default Setup Screen Overview

The panels in the Default Settings screen include all the parameters choices that are saved to
a mold setup file on the following screens/locations:
• Drop-down menus in the Quick Set screen
• Staging Screen (Staged Startup 1-4)
• Staging Screen (Staged Shutdown 1-4)
• Mold Test Setup screen
After a parameter has been changed, it is automatically saved and will be applied to the next
new mold setup that is created. To change a parameter, do the steps that follow:
1. Select the white field that contains the parameter value to the right of the parameter
label.
2. Enter the new value or select the setting in the dialog box.
NOTE: Depending on the type of value, this could be a numeric keypad or a list dialog
box.

3. Touch the button to accept the change.

If you find it necessary to return all settings in the Default Settings screen to the factory
defaults, select the Reset to Default Values button.

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6.3.2 Default Settings Screen Default Parameters

Table 6-5 describes the default parameters on the Default Settings screen.

Table 6-5 Default Parameters

Default Value
Panel Available Parameters
(Imperial/Metric)
Temperature Setpoint 350 °F / 177 °C
Power Setpoint 10%
Frequently Used Regulation Mode Auto

Alarm Window 10 °F / 6 °C
Abort Window 20 °F / 11 °C
Groups Group 1-10 Name Blank - User Definable

Temperature Minimum 32 °F / 0 °C
Setpoint Limits Temperature Maximum 932 °F / 500 °C

Power Minimum 0%

Power Maximum 30%

Temperature Setpoint 250 °F / 121 °C

Temperature Minimum 100 °F / 38 °C

Temperature Maximum 250 °F / 121 °C

Manual Standby
Power Setpoint 10%

Power Minimum 0%

Power Maximum 30%

Duration Timer 00:00:00

Temperature Setpoint No Change

Temperature Minimum 100 °F / 38 °C

Temperature Maximum 700 °F / 371 °C

Manual Boost
Power Setpoint 10%

Power Minimum 0%

Power Maximum 30%

Duration Timer 00:00:00

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Table 6-5 Default Parameters (Continued)

Default Value
Panel Available Parameters
(Imperial/Metric)
Temperature Setpoint 250 °F / 121 °C

Temperature Minimum 100 °F / 38 °C

Temperature Maximum 700 °F / 371 °C

Power Setpoint 10%

Power Minimum 0%
Remote Standby
Power Maximum 30%

Duration Timer 00:00:00

Delay 00:00:00

Input Mode Direct

Reset Delay Timer in Direct Mode Not Selected

Temperature Setpoint No Change

Temperature Minimum 100 °F / 38 °C

Temperature Maximum 700 °F / 371 °C

Power Setpoint 10%

Remote Boost
Power Minimum 0%

Power Maximum 30%

Duration Timer 00:00:00

Delay 00:00:00

Input Mode Direct

Heater Types Custom Type 1-8 Type 1-8

Output Power Limit 100%

Output Mode Zero Cross

PCM - Priority Control System

AMC On
Advanced
Settings Earth Leakage Check On

Earth Leakage Limit 0.500A

No Response Limit 4Min

No Heater Limit 0.200A

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Table 6-5 Default Parameters (Continued)

Default Value
Panel Available Parameters
(Imperial/Metric)
Control Made ART

P - Proportional 15

I - Integral 2
Control Settings
D - Derivative 2

P - ART 15

I - ART 2

D - ART 2

Tuning Strategy ART 2.0

ART No ART

Minimum P 6

Minimum I 3

Minimum D 0
ART Settings
Default P 50

Default I 1

Default D 0

ART Offset 50 °F / 10 °C

Enable Not Selected

Run Last Stage Indefinitely Not Selected

At Temp Window 5 °F / 3 °C
Stage 1-4 Soak Timer 00:00:00

Stage 1 Temperature Off

Stage 1 Power Off

Staged Startup
Stage 2 Temperature (Off)

Stage 2 Power (Off)

Stage 3 Temperature (Off)

Stage 3 Power (Off)

Stage 4 Temperature (Off)

Stage 4 Power (Off)

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Table 6-5 Default Parameters (Continued)

Default Value
Panel Available Parameters
(Imperial/Metric)
Enable Not Selected

Override Limit 00:15:00

At Temp Window 5 °F / 3 °C

Stage 1-4 Soak Timer 00:00:00

Stage 1 Temperature (350 °F) / (177 °C)

Stage 1 Power (50%)

Staged
Shutdown Stage 2 Temperature (350 °F) / (177 °C)

Stage 2 Power (50%)

Stage 3 Temperature (350 °F) / (177 °C)

Stage 3 Power (50%)

Stage 4 Temperature (350 °F) / (177 °C)

Stage 4 Power (50%)

Validate Zone After 20 °F / 11 °C

Fixed Start Setpoint 300 °F / 149 °C

Use Fixed Setpoint Not Selected

Zone Cooling Time 00:00:10

Mold Test and
Maximum Test Time 00:02:00
Results
Amps Tolerance 5%

VAC Tolerance 5%

Ohms Tolerance 5%

Watts Tolerance 5%

6.3.3 Import/Export Default Settings

The Neo5 has an Export and Import Settings function for transferring a file that contains the
Default settings, configured in the Default Settings screen, to a USB flash drive. This file can
be imported to another Neo5 controller to simplify the Default Settings setup.
The filename format is: Default_[date]_[time].settings
Example: Default_2021-01-01_09-30-00_settings
The sections that follow give instructions about the import and export of Default screen
settings.

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6.3.3.1 Export Default Screen Settings

After you have set your Default screen settings, do the steps the follow:
1. Insert a USB flash drive into the USB port on the Neo5 controller.
2. Select the System Setup button on the Neo5 Home screen or in the screen header.

3. In the Default Settings area of the System Setup screen, select the Export Settings
button (refer to Figure 6-6).

Figure 6-6 Export Default Screen Settings

A dialog window will show to say that the file was exported successfully.

4. Select the button to close the dialog.

5. Remove the USB drive from the USB port.

6.3.3.2 Import Default Screen Settings

To import Default screen settings, do the steps the follow:
1. Insert the USB flash drive with the Default screen settings file into the USB port on the
Neo5 controller.
2. Select the System Setup button on the Neo5 Home screen or in the screen header.

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3. In the Default Settings area of the System Setup screen, select the Import Settings
button (refer to Figure 6-7).

Figure 6-7 Import Default Screen Settings

A dialog window will show that lists the saved Default screen settings files on the USB
drive (refer to Figure 6-8).

Figure 6-8 Select an Import File

4. Select the file that you want to import and then select the button to close the
dialog.
A dialog window will show to say that the settings were imported successfully.

5. Select the button to close the dialog.

6. Remove the USB drive from the USB port.

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Chapter 7 Mold Setups

The mold setup has the process parameters necessary to operate the hot runner system.

7.1 File Management Screen

The File Management screen stores and manages files such as mold setups, images,
documents and reports. Files are stored in mold, system, and user folders. Each mold folder
allows the storage of mold setups, images and documents associated with that specific mold.
The screen is divided into two panes. The left side shows all directories that are on the Neo5
hard drive and the right side shows all available directories and files from an external source,
such as a USB or a network file share.
To access the File Management screen, select the File Management button on the Neo5
Home screen in the System Configuration group. You can also select the File Management
button in the footer of any screen.

The File Management screen shows (refer to Figure 7-1).

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Figure 7-1 File Management Screen

You can use the File Directory checkboxes at the top right of the screen, to see just the mold
files or the other system files. If Molds is selected, all the mold folders will be shown in the left-
hand pane. If System is selected, the Reports folder, containing all system files will be shown.

The Details checkbox displays the files in a tabular layout that lets you see additional
information about the files:
• File name
• File size
• Date and time that the file was modified

You can use the File Type Filter checkboxes at the top left of the screen to filter the files you
want to see in the left pane.

The File Type Filter selections are:

• Setups - shows the mold setup files stored in the Molds folders if Molds is selected in the
File Directory.
• Images - shows image files stored in the Molds folders if Molds is selected in the File
Directory.

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• CSVs - shows all Comma Separated Value (CSV) files stored in the Molds folders if Molds
is selected in the File Directory.
• All - shows all available file types stored in the Molds folders if Molds is selected in the
File Directory.
Select the USB checkbox to display the contents of a connected USB device. Select the
Network checkbox to display the contents of a network folder if the system is configured for
a network.

Table 7-1 describes the File Management screen buttons.

Table 7-1 File Management Screen Buttons

Button Description
Touch the New Mold Setup or Mold Folder button to create a new mold
setup file or mold folder. This button is not enabled if system is selected.

Touch the Load Mold Setup button to load a mold setup file. This button
is not enabled unless a mold setup file is selected. The default setup file
cannot be loaded directly.

Touch the Save As button to save the currently loaded mold setup file
with a new name. This action only applies to the loaded mold setup file
regardless of what is selected on the screen.

Touch the Copy button to copy mold setups, images, or CSV files from one
folder or device to another.

Touch the Delete button to delete a mold folder, mold setup, image or
CSV file. A confirmation message is shown. This button is not available
unless a folder or file is selected.

Touch the Rename button to display a keyboard to rename a mold folder,

mold setup, image, or CSV file. This button is not enabled unless a file or
folder is selected.

Touch the Preview button to display mold setup files, images, and CSV
files.

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7.1.1 Save Changes to a Mold Setup File

After a mold setup file has been loaded, you can permanently save changes made to it.
1. On the Mold Setup screen, touch the Save Changes button. This will show the Mold
Setup - Save dialog box to confirm the mold and name of the file that the changes are
to be saved to.

2. Touch . Changes are saved.

7.1.2 Save the Current Mold Setup File as a New File

Once a Mold Setup file has been loaded, it can be saved as a new file.
To save the currently loaded Mold Setup file as a new file, do the steps that follow:
1. On the File Management screen, touch the Save As button. This will show the keyboard
(refer to Figure 7-2).

Figure 7-2 Mold Save As Screen

2. Enter the new mold name, then touch to accept the name.

7.1.3 Load an Existing Mold Setup File

After a Mold Setup file has been created it is automatically loaded as the current Mold Setup
in the system.

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To load a different Mold Setup, do the following:

1. On the File Management screen, select the Mold Setup folder that contains the Mold
Setup file to be loaded.
2. Touch the name of the mold setup file to be loaded.
3. Touch the Load Mold Setup button to load the selected mold setup.
Once a mold setup is loaded, its name will be displayed at all times on the Mold Setup
Info button in the System Footer.

7.1.4 Delete Files

When a file or folder is no longer required on the internal hard drive, you can delete it.
1. On the File Management screen, touch the file or folder to be deleted.
2. Touch the Delete button.
3. A message appears asking to confirm the deletion. To continue, touch . To cancel
the deletion, touch .

7.1.5 Copy Files

You can copy mold setups, images, or CSV files from one folder or device to another.
To copy and paste a file, do the following:
1. On the File Management screen, touch the file to be copied.

2. Touch the Copy button .

3. Navigate to the destination folder or pane, and touch anywhere in the pane or folder.

7.1.6 Transfer Data

7.1.6.1 Transfer Data to the Network

Use the File Management screen to transfer data to the network. When connected to the
network, the network folder structure appears by default in the right pane of the File
Management screen.

7.1.6.2 Transfer Data Using a USB Storage Device

You can transfer data using USB disks or USB CD-ROM drives. Select the USB button on the
File Management screen. When a USB device is plugged into the USB port, the folder
structure of the USB device appears in the right pane of the File Management screen. The
folder structure disappears when the device is unplugged. Follow the copy and paste steps
to move files from the USB device to the local hard drive, or from the local hard drive to the
USB device.

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Chapter 8 Process Adjustments

You can adjust the process settings for a mold setup before starting the mold, or while the
mold is running. This chapter explains how to use, monitor, and modify the system.
Neo5 allows zone data to be shown in different graphical and textual formats. These include
tabular views, images, and views that are divided into groups of zones.

8.1 Zone Selection

Multiple zones can be selected from the screens that follow:

• Multi-Group View
• Text View
• Quick Set
• Neo2 View
• Staging
• Mold Test
• Mold Test Results
• Zone Calibration
• Zone Slot Configuration
• CAN Info
You can select zones four ways:
NOTE: When a zone is selected, its color will change to yellow.
• Touch a zone. The zone is selected.

• Touch . This selects all the available zones.

• Use the Block function. Touch and hold a zone element for more than a second. This will
highlight the zone green. Then touch another zone. All the zones between the start and
end zone are highlighted (selected).

• Touch a zone and drag your finger. All the zones that your finger passes over are
selected. This is a zone selection option on all the screens except the Neo5 View.

Touch to deselect all of the selected zones.

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8.2 Zone Groups

You can make groups of zones with the use of the Quick Set screen. The groups let you easily
identify selections of zones are used in the mold. When a group of zones is select, process
adjustments can be made to all zones in the group at one time. Adjustments to zones would
not have to be made individually.
To use zone groups, make the groups by giving them identifiable names and then add
selected zones to the groups. The sections the follow describe how to make groups, add
zones, remove zones, and delete a group.
NOTE: For more information on the use of the Quick Set screen, refer to Section 8.7.

8.2.1 Make Zone Groups

Do the steps that follow to create groups:
NOTE: You can make a maximum of 10 groups.
1. On the Neo5 Home screen, select the Quick Set button in the Temperature
Management group (refer to Figure 8-1).

Figure 8-1 Quick Set Button

2. On the Quick Set screen, select the Groups button to open the drop-down menu (refer
to Figure 8-2).

Figure 8-2 Groups Drop-Down Menu on the Quick Set Screen

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3. Do the steps that follow to assign names to one or more of the groups (1 through 10, as
necessary):
a. Touch the field to the right of the Group 1 Name.
b. Use the keyboard to enter in the name you want for the group, then select the
button to accept the name (refer to Figure 8-3).
NOTE: Above the keys on the keyboard, there is a selection of buttons with
common names used for groups. If you want, touch a button to select one of
these names, and the name will be entered in the name field.
c. As necessary, do step a and step b again to enter more group names (Group 2
through Group 10 Names).

Figure 8-3 Group Name Keyboard Dialog

The group names will be at the bottom of the Quick Set screen (refer to Figure 8-4). When you
touch the group name button, the zones in the group are highlighted. With the group button
selected, you can set or change the parameters for all the zones in that group at one time.

Figure 8-4 Group Buttons at the Bottom of the Quick Set Screen

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8.2.2 Add Zones to Groups

Do the steps that follow to assign zones to a group:
1. Select the zones that you want to be in a group.
2. Touch the field to the right of the Group button at the top of the Groups drop-down
menu.
3. Select a group name from the list of groups in the Group selection dialog that shows
(refer to Figure 8-5).

Figure 8-5 Group Selection Dialog

4. Select the button to accept the group assignment.

5. As necessary, do step 1 through step 4 again to assign zones to the groups that remain.
With the zones added to the groups, you can select a group button at the bottom of the
screen and the zones in that group will be highlighted (refer to Figure 8-6).

Figure 8-6 Group Selected

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8.2.3 Remove a Zone from a Group

Do the steps that follow to remove a zone from a group:
1. Select the zone that you want to remove from the group.
2. Touch the field to the right of the Group button at the top of the Groups drop-down
menu.
3. Select None at the top of groups in the Group selection dialog that shows (refer to
Figure 8-5).

4. Select the button to accept the zone removal.

8.2.4 Delete a Group

Do the steps that follow to delete a group:
1. Touch the box to the right of the Group X Name.
2. On the group name keyboard dialog, select keyboard erase button (at the right of
the name field) to delete the name, then select the button.

8.3 Multi-Group View Screen Overview

Use the Multi Group View screen to see all user-configured zone groups. Refer to Figure 7-3.
Each group has its own controls to synchronously energize or de-energize all zones in the
group and put them into standby or boost mode.
For information about how to make zone groups, refer to Section 8.2.
On the Neo5 Home screen, in the Zone Views group, select the Multi-Group View button.

The Multi-Group View screen will show (refer to Figure 8-7).

All the groups that were set up in the Quick Set groups screen will be shown.
Touch the column heading to sort the information in that column. A red line at the top of the
column header tells you that the information is in ascending order.
Select a one zone or a block of zones to automatically open the Quick Set screen with that
zone or block of zones selected.

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Figure 8-7 Multi-Group View Screen

You can change the screen to Full Screen view to see more information for the zones. Touch
the Plus/Minus button to see the Full Screen view. Touch the button again to change back to
Half Screen view.

Figure 8-8 Multi-Group View Screen - Full Screen View

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The buttons on the Multi Group View screen are described in Table 8-1.

Table 8-1 Multi Group View Screen Buttons

Button Description
Expands all group information lists.

Collapses all group information lists.

Lets you define the group layout order. You can select the order that
you would like to see the groups shown from the top to the bottom of
the screen. The default is the groups are shown in alphabetical order.

Collapses the related group information list.

De-energizes the zones in that group if they are energized.

Energizes the zones in that group if they are not energized.

Sets the zones in this group to manual standby. More than one group
can be put in standby at the same time. This button will not operate if
one or more groups are in boost mode.

Sets the zones in this group to manual boost. More than one group
can be put in boost mode at the same time. This button will not
operate if one or more groups are in standby mode.

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Table 8-1 Multi Group View Screen Buttons (Continued)

Button Description
Opens the Quick Set screen with all of the zones automatically
selected.
NOTE: In the header of a group, this button opens the Quick Set
screen with all zones selected in the group. At the lower left
corner of the screen, this button opens the Quick Set screen
with all zones selected.

Lets you change the group header colors.

8.3.1 Group Controller Function Buttons

The group controller function buttons let you control the zones in a group (refer to
Figure 8-9). You can energize or de-energize a group’s zones, and also set the zones in
standby and boost mode.

Figure 8-9 Group Controller Function Buttons

NOTE: The Stop, Start, Standby, and Boost buttons at the top left corner of the screen
operate all zones and override the group zone settings.

8.3.2 Define Group Layout Order

You can select the order in which the groups are shown on the Multi-Group View screen. The
default setting is to show the groups in alphabetical order from the top to the bottom of the
screen. Touch the Define Group Layout Order button to select the order you want.

Do the steps that follow to set the group order:

1. If necessary, touch the Clear Previous button or clear all button to clear the numbers.
2. Touch the box for the group that you want to be at the top (1st position) on the Multi-
Group View screen (refer to Figure 8-10).
The number 1 will show in the box.

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3. Continue to touch the boxes to put the groups in the order that you want to see them.

Numbers will be shown in order with each group box that you select.
4. Touch the button to accept the changes.
The groups will be arranged with the number 1group on top (in the full view screen). In the
half screen view, the groups are arranged top to bottom and left to right.

Figure 8-10 Define Group Layout Order Dialog

Figure 8-11 shows the groups are in the order selected in Figure 8-10.

Figure 8-11 Groups in Order Selected

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8.3.3 Change Header Colors

To help identify a group, you can select a header color for that group that is shown on the
Multi Group View screen. To change the header color, do the steps that follow:

1. On the group header bar, select Change Color button.

The Select a Color dialog shows (refer to Figure 8-12).

Figure 8-12 Select a Color Dialog

2. Select the color and then touch the button.

The header for the group changes to the color you select, as shown in Figure 8-13.

Figure 8-13 Group Header Color Example

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8.3.4 Collapse and Expand Zones Shown in a Group

You can collapse the zones in a group, so they are not shown. Only the group header is
shown. This makes it easy to see only the group zones you want shown on the screen. To
collapse the zones in a group, select the down arrow at the left of the group header.

Figure 8-14 shows the zones collapsed in the Probes and Manifolds groups.

Figure 8-14 Zones Collapsed in Groups

To expand the zones in a group, select the right arrow at the left of the group header.

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8.4 Neo View Screen Overview

The Neo View shows the zones in a graphical format. It is designed to provide an easy way to
view the overall status of the mold without having to sort through detailed data.
On the Neo5 Home screen, in the Zone Views group, select the Neo View button.

The Neo View screen will show (refer to Figure 8-15).

Figure 8-15 Neo View Screen

Table 8-2 describes the details of the temperature bars that

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Table 8-2 Temperature Bar

Temperature Bar Description

The bar in each zone shows the temperature of the zone.
Segments of the bar are color coded.
• The green area represents the molding window.
• The white hairline represents the setpoint.
• An arrow represents the actual temperature.
• If the arrow is yellow, the temperature is not within the graph range.

• The arrow turns black when the temperature is in the range of the
graph and moves up until it gets to the set point.

• The yellow area in the zone bar represents the alarm window
• The red and blue areas in the zone bar represent the high (red) and low
(blue) abort windows.
• A blank gray bar indicates that the zone is off.

• When the arrow points to the white hairline, the zone is At Temperature.

As an example, Figure 8-16 shows that zones 003 through 012 are At Temperature, while
zones 001 and 002 are off.

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Figure 8-16 Neo View Operation Example

Touch the Plus/Minus button and the screen will only show the temperatures of the zones
(refer to Figure 8-17). Touch the button again to toggle back to the graphical view.

Figure 8-17 Neo View With Only Temperatures Shown

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8.5 Text View Screen Overview

The Text View screen gives zone information in a tabular format (refer to Figure 8-18). The
screen is used to access detailed data for each zone and gives the most comprehensive view
of the process.
On the Neo5 Home screen, in the Zone Views group, select the Text View button.

Figure 8-18 Text View Screen

Table 8-3 describes the items on the Text View screen.

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Table 8-3 Text View Screen Descriptions

Item Description
Zone Row Each row in the Text view represents a heating zone in the system.
Touching anywhere within the row will navigate to the Quick Set screen.
Refer to 8.7.

Column Headers Each header in the Text view indicates what information is being
displayed in each column.
• Zone = Zone number
• Name = Zone name
• Setpoint = Zone setpoint
• Temp = Actual temperature of zone
• PWR = Power output to the heater
• Amps = Current draw of heater (values in this column are
suppressed for XL and HL cards)
• Leakage = Earth leakage. This column is only displayed if the
Display Earth Leakage Reading is selected in the Earth Leakage
section of the system setup screen
• Reg = Control mode (Auto = T/C control, Manual = Fixed % output,
Monitor = Temperature only - No power output)
• Alarm = Alarm window (degrees above and below setpoint before
an alarm condition is declared)
• Abort = Abort window (degrees above and below setpoint before
an abort condition is declared)
• Watts = Calculated wattage of each heater (values in this column
are suppressed for XL and HL cards)
• Ohms = Calculated full load ohms of the heater, based on the circuit
test results (values in this column are suppressed for XL and HL
cards)
• Full Load = Calculated full load wattage of the heater, based on the
circuit test results (values in this column are suppressed for XL and
HL cards)
• Volts = Measured line voltage that supplies power to each heater

Scroll Bar Use the scroll bar to scroll between pages within a screen. If all of the
available data fits in a single page, then the scroll bar will not be
displayed

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8.5.1 Zone Selection on the Text View Screen

You can select one or multiple zones on the Text View screen that you want to work with on
the Quick Set screen. To select one zone, touch anywhere on the zone row and the Quick Set
screen will show with that zone highlighted.
To select multiple zones, touch a zone row and drag your finger up or down to the last zone
you want to select. The zone rows are highlighted as you drag your finger along the rows.
When you release your finger from the screen, the Quick Set screen will show with the
selected zones highlighted.

8.5.2 Sorting
You can sort column data on the Text View screen and all other screens that have column
headers. Touch the column header field. The ascending or descending arrows ( ) are
shown next to the column header name. Touch the column header to reverse the order.
Information can be sorted according to the dynamic columns (for example, current (Amps),
voltage (Volts), etc.). This can help you see which zone draws the most current at a particular
moment.

8.6 Quick Adjustment Panel

When you select a zone, a block of zones, or touch the ‘Select All Zones’ button on the Neo
View or Text View screens, the Quick Adjustment panel will show on the right side of the
screen (refer to Figure 8-19). This panel makes it easy for you to change frequently used
parameter settings without opening the Quick Set screen.

Figure 8-19 Quick Adjustment Panel

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The Quick Adjustment panel lets you change the current setpoint, zone on/off, and
regulation (Auto or Manual) with the use of the buttons in the panel. You will see the zone
information change immediately after a panel function is selected.
Use the buttons in the Current Setpoint area of the panel to increase or decrease the zone
temperatures by 1°, 5°, or 10°. Use the buttons in the Zone On/Off area of the panel to enable
or disable one or more zones. Use the buttons in the Regulation area of the panel to change
one or more zones to Auto or Manual mode.
The Quick Set button, at the bottom right of the panel, will automatically open the Quick Set
screen. Zones selected in the Neo View or Text View screens will also be selected in the Quick
Set screen.
The Cancel button will close the Quick Adjustment panel and de-select any zones previously
selected.

8.7 Quick Set Screen

Use the Quick Set screen to change the available zone settings and to put zones into groups.
On the Neo5 Home screen, in the Temperature Management group, select the Quick Set
button to see the Quick Set screen (refer to Figure 8-20).

NOTE: For information about zone groups, refer to Section 8.2.

NOTE: When you select a zone in the Neo View, Multi-Group View, or Text View screens the
Quick Set screen will automatically show.
On the left side of the Quick Set screen, the zone setpoint fields are organized into drop-
down tabs. Touch a tab to see the fields it contains.
Touch the box to the right of a field to show a keypad, keyboard, or selection menu. Refer to
Figure 4-4 for more information about these entry dialogs.

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Figure 8-20 Quick Set Screen

8.7.1 Frequently Used Fields

The Frequently Used fields are the settings you may go to most often (refer to Figure 8-21).

Figure 8-21 Frequently Used Fields

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The Frequently Used fields are described in Table 8-4.

Table 8-4 Frequently Used Fields

Item Description
Temperature Setpoint Touch this field to set the temperature for one or more zones.

Power Setpoint Touch this field to set the percentage of power output for one or more
zones that are in Manual regulation.

Zone On/Off Touch this field to set the selected zone(s) ON or OFF. A dialog window
shows that lets you select the status. The default is ON.

Regulation Mode Use this field to set the regulation mode for the selected zone(s):
• AUTO or Automatic (closed loop) - the system uses a thermocouple
feedback to control the temperature.
• MAN or Manual (open loop) - the system will only apply user-
selected power (0 to 100%) to the heater and not use the
thermocouple feedback.
• MON or Monitor - the system will only monitor the temperature of a
thermocouple (no power output).

Alarm Window Touch this field to set the upper and lower alarm limits.

Abort Window Touch this field to set the upper and lower abort limits.

8.7.2 Zone Edit

The Zone Edit drop-down tab is shown in Figure 8-22.

Figure 8-22 Zone Edit Fields

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The Zone Edit fields are described in Table 8-5.

Table 8-5 Zone Edit Fields

Item Description
Zone Name Touch this field to give a custom name to a zone or group of zones.

Group Name Touch this field to give a name to a group of selected zones. When a
group of zones is given a name, that name shows as a button at the
bottom of the Quick Set screen. Touch a group button and the zones in
the group are highlighted.
All zones given a group name are used to create group views in the Multi
Group View screen.

Zone Locked/Unlocked Touch this field to lock or unlock the selected zone(s). If a zone is locked,
it will prevent any changes from being made to it from the Quick Set
screen.

Display/Hide Zone Touch this field to Display or Hide the selected zone(s). If Hide is selected,
the zone(s) will be removed from all the zone data view screens.

8.7.2.1 Zone Name

With one or more zones selected, touch the box to the right of the Zone Name button.
Use the keyboard to name the zone(s) or groups (refer to Figure 8-23). Eight common zone
name tabs are above the keyboard. Touch the common name tab to assign that name to the
zone(s).

Figure 8-23 Zone Name Keyboard

After you name all the zones, you can auto assign numbers to the zones. Touch the Auto+
button. The Auto+ assigns a number, in sequential order, to all the zones.

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8.7.2.2 Locked/Unlocked
You can lock one or more zones, so they cannot be changed on the Quick Set screen.
Select the zones you want to lock and then touch the box to the right of the
Locked/Unlocked button. The Locked/Unlocked dialog shows (refer to Figure 8-24).
Select Locked or Unlocked and then select to accept the change.

Figure 8-24 Zone Locked/Unlocked Selection Dialog

8.7.2.3 Display/Hide
You can hide unused zones from the Neo View, Multi-Group View, and Text View screens. The
zones will not show on those three screens.
To hide one or more zones, you must change the status of the zone(s) to OFF. If a selected
zone is ON, then the function to hide the zone is disabled. With a zone status changed to OFF
the hide function is enabled, as shown in Figure 8-25.

Figure 8-25 Hide Function Enabled

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Select the zones that are OFF and then touch the box to the right of the Display/Hide button.
The Zone Displayed/Hidden dialog shows (refer to Figure 8-26).
Select Hide and then select the button to accept the change.
For zones you want to be seen again, select Display and then select the button to
accept the change.

Figure 8-26 Zone Hide Dialog

8.7.3 Groups
Refer to Section 8.2.

8.7.4 Setpoint Limits

The Setpoint Limits drop-down tab is shown in Figure 8-27.

Figure 8-27 Setpoint Limits Fields

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The Setpoint Limits fields are described in Table 8-6.

Table 8-6 Setpoint Limits Fields

Item Description
Temperature Minimum These values specify the range limits in which the Temperature Setpoint
field can be set. Example: If the Minimum is set to 100°F and the
Temperature Maximum
Maximum to 600°F, you will not be able to enter a setpoint that is less
than 100°F or more than 600°F.

Power Minimum These values specify the percentage range limits in which the Power
Power Maximum Setpoint field can be set.

8.7.5 Manual Standby

The Manual Standby drop-down tab is shown in Figure 8-28.

Figure 8-28 Manual Standby Fields

The Manual Standby fields are described in Table 8-7.

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Table 8-7 Manual Standby Fields

Item Description
Temperature Setpoint The temperature to which all zones are set when the Standby button is
touched. This setting can be used to lower all zone temperatures to their
Manual Standby temperature setpoint until the timer completes or the
user touches the Standby button again. Possible values are 0 to 500 °C or
32 to 932 °F. The default value is 121 °C or 250 °F.

Temperature Minimum These values specify the range limits in which the Standby temperature
Temperature Maximum can be set.

Power Setpoint The power output to which all zones are set when the Standby button is
touched. This setting can be used to lower all zone power setpoints to
their manual standby power setpoint until the timer completes or the
user touches the Standby button again. Possible values are 0% – 100%.
The default value is 10%.

Power Minimum These values specify the percentage range limits in which the Standby
Power Maximum power can be set.

Duration Timer This sets the time that the zones will stay in the manual standby mode. To
cancel the manual standby duration timer at any time, touch the Start or
Stop buttons.
NOTE: This setting applies to all zones.

Table 8 -8 Manual Standby Operational Description

Delay Remote
Manual Time Input Mode Operation - STANDBY Button Select
Time Time
0:00:00 ---- ---- ---- System enters Standby indefinitely.

X:XX:XX ---- ---- ---- System remains in Standby until the timer
expires.

To cancel the Manual Standby duration timer, touch the Start or Stop buttons.

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8.7.6 Manual Boost

The Manual Boost drop-down tab is shown in Figure 8-29.

Figure 8-29 Manual Boost Fields

The Manual Boost fields are described in Table 8-9.

Table 8-9 Manual Boost Fields

Item Description
Temperature Setpoint The temperature to which all zones are set when the Boost button is
touched. This setting raises all zones to their manual boost setpoint until
the timer completes or the user touches the Boost button again. Possible
values are 0 to 500 °C or 32 to 932 °F. The default value is No Change.

Temperature Minimum These values specify the range limits in which the Boost Temperature can
Temperature Maximum be set.

Power Setpoint The power values to which all zones are set when the Boost button is
touched. This setting raises all zones to their manual boost setpoint until
the timer completes or the user touches the Boost button again. Possible
values are 0% – 100%. The default value is 90%.

Power Minimum These values specify the percentage range limits in which the Boost
Power Maximum power can be set.

Duration Timer This sets the time that the zones will stay in the manual boost mode. To
cancel the manual boost duration timer at any time, touch the Start or
Stop buttons.

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Table 8 -10 Manual Boost Operational Description

Delay Remote
Manual Time Input Mode Operation - BOOST Button Select
Time Time
0:00:00 ---- ---- ---- System enters Boost indefinitely.

X:XX:XX ---- ---- ---- System remains in Boost until the timer
expires.

8.7.7 Remote Standby

The Remote Standby drop-down tab is shown in Figure 8-30.

Figure 8-30 Remote Standby Fields

The Remote Standby fields are described in Table 8-11.

Table 8-11 Remote Standby Fields

Item Description
Temperature Setpoint Remote standby is started by a digital input signal from the IMM. This
setting lowers all zones to their remote standby temperature setpoint
until the timer completes or the input signal is off. Possible values are 0
to 500 °C or 32 to 932 °F. The default value is 121 °C or 250 °F.

Temperature Minimum These values specify the range limits in which the Remote Standby
Temperature Maximum Temperature can be set.

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Table 8-11 Remote Standby Fields (Continued)

Item Description
Power Setpoint Remote standby is started by a digital input signal from the IMM. This
setting lowers all zones to their remote standby power setpoint until the
timer completes or the input signal is off. Possible values are 0% – 100%.
The default value is 10%.

Power Minimum These values specify the percentage range limits in which the Remote
Power Maximum Standby Power can be set.

Duration Enter the time that the zones will stay in the remote standby mode. This
setting that applies to all the zones. To cancel the remote standby
duration timer at any time, touch the Start or Stop buttons (only when in
the Trigger or ON/OFF modes).

Delay Enter the time that you want the system to wait from the time it receives
the remote standby signal to when it enters the standby mode. This
setting that applies to all the zones.

Input Mode Set to one of the three modes.

• Direct
• On/Off
• Trigger
Refer to Table 8 -12.

Reset Delay Timer in When enabled, this allows you to reset the delay timer by touching the
Direct Mode Standby button in the system header. The Reset Delay Timer is only used
when in Direct Mode and while the delay timer is in operation.

Table 8 -12 Remote Standby Operational Description

Manual Remote
Delay Time Input Mode Operation - STANDBY Button Select
Time Time
---- 0:00:00 0:00:00 Trigger System will not enter Standby since no
timers are set.

---- 0:00:00 X:XX:XX Trigger System immediately enters and remains in

Standby until the timer expires.

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then
enters Standby until the timer expires.

---- X:XX:XX 0:00:00 Trigger System delays for specified time and then
enters Standby indefinitely.

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then
enters Standby until the timer expires. If the
input signal changes state while delay timer
is active, the delay timer is reset to the
specified value.

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Table 8 -12 Remote Standby Operational Description (Continued)

Manual Remote
Delay Time Input Mode Operation - STANDBY Button Select
Time Time
---- X:XX:XX 0:00:00 Trigger System delays for specified time and then
enters Standby indefinitely. If the input
signal changes state while the delay timer is
active, the delay timer is reset to the
specified value.

---- 0:00:00 0:00:00 ON/OFF System enters Standby until the input signal
is not active.

---- 0:00:00 X:XX:XX ON/OFF System enters Standby until the input signal
is not active or the timer expires.

---- X:XX:XX X:XX:XX ON/OFF System delays for specified time and then
enters Standby until the signal is not active
or the timer expires.

---- X:XX:XX 0:00:00 ON/OFF System delays for specified time and then
enters Standby until the input signal is not
active.

---- ---- ---- Direct System enters Standby until the input signal
is not active. If the input signal is active
when the system is started, it will
immediately go into Standby mode.

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8.7.8 Remote Boost

The Remote Boost drop-down tab is shown in Figure 8-31.

Figure 8-31 Remote Boost Fields

The Remote Boost fields are described in Table 8-13.

Table 8-13 Remote Boost Fields

Item Description
Temperature Setpoint The temperature all zones are set to when a remote boost signal is
received.
Remote boost is started by a digital input signal from the IMM. This
setting raises all zones to their remote boost setpoint until the timer
completes or the input signal is off. Possible values are 0 to 500 °C or 32
to 932 °F. The default value is No Change.

Temperature Minimum These values specify the range limits in which the Remote Boost
Temperature Maximum Temperature can be set.

Power Setpoint The power level that all zones are set to when a remote boost signal is
received.
Remote boost is started by a digital input signal from the IMM. This
setting raises all zones to their remote boost setpoint until the timer
completes or the input signal is off. Possible values are 0% – 100%. The
default value is 90%.

Power Minimum These values specify the percentage range limits in which the Remote
Power Maximum Boost Power can be set.

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Table 8-13 Remote Boost Fields (Continued)

Item Description
Duration The time that the zones will stay in the remote boost mode.
NOTE: This setting applies to all zones.
Delay The time that you want the system to wait from the time it receives the
remote boost signal to when it enters the boost mode.

Input Mode Set to one of the three input modes:

• Direct
• On/Off
• Trigger

Table 8 -14 Remote Boost Operational Description

Manual Delay Remote Input

Operation - Boost Button Select
Time Time Time Mode
---- 0:00:00 0:00:00 Trigger System will not enter Boost since no timers are set.

---- 0:00:00 X:XX:XX Trigger System immediately enters and remains in Boost
until the timer expires.

---- X:XX:XX X:XX:XX Trigger System delays for specified time and then enters
Boost until the timer expires.

---- X:XX:XX 0:00:00 Trigger System delays for specified time and then enters
Boost indefinitely.

---- 0:00:00 0:00:00 ON/OFF System enters Boost until the input signal is not
active.

---- 0:00:00 X:XX:XX ON/OFF System enters Boost until the input signal is not
active or the timer expires.

---- X:XX:XX X:XX:XX ON/OFF System delays for specified time and then enters
Boost until the input signal is not active or the
timer expires.

---- X:XX:XX 0:00:00 ON/OFF System delays for specified time and then enters
Boost until the signal is not active.

---- ---- ---- Direct System enters Standby until the input signal is not
active. If the input signal is active when the system
is started, it will immediately go into Standby
mode.

To cancel the Remote Boost, touch the Start or Stop buttons (only when in the Trigger or
ON/OFF modes).

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8.7.9 Heater Types

The Heater Types drop-down tab is shown in Figure 8-32.

Figure 8-32 Heater Types

Use this screen to assign a heater type to one or more zones.

To assign a heater type, do the steps that follow:
1. Assign a name to one or more of the Custom Heater Types (1 thru 8) shown in the drop-
down list.
a. Touch the field to the right of the Custom Type 1. The Custom Heater Type Name
keyboard is shown (Figure 8-33).

Figure 8-33 Custom Heater Type Name Keyboard

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b. Use the keyboard to enter in the heater type name or select one of the nine heater
type names and then select the button.

c. As necessary, do step a and step b again to enter the Custom Type 2 through
Custom Type 8 names.

2. Select the zones that you want assigned to a specific heater type.
3. Touch the field to the right of Heater Type.
4. In the Heater Type dialog box that shows (Figure 8-34), touch the heater type that you
want to assign to the selected zones and then select the button.

Figure 8-34 Heater Type Dialog

5. As necessary, do step 2 through step 4 again to assign heater types to other zones or
groups.

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8.7.10 Advanced Settings

The Advanced Settings drop-down tab is shown in Figure 8-35.

Figure 8-35 Advanced Settings

The Advanced Settings fields are described in Table 8-15.

Table 8-15 Advanced Settings Fields

Item Description
Output Power Limit Set the maximum percentage of power output that the system can
supply to the heat zone(s).

Assign Leader Zone Enter the number of a leader zone that a selected zone will follow. If the
selected follower zone’s thermocouple fails, Neo5 will use the power
output of the leader zone for the follower zone. This will let the selected
follower zone continue to operate without the defective thermocouple.
Refer to Section 8.7.13.

Sensor Input Enter the number of the thermocouple that is connected to the zones.
The match zone button will select the thermocouple with the same
number as the zone.

Output Mode Select the type of output mode that will be used to control the zones.
Choose Zero Cross or Phase Angle.

PCM - Priority Control For the Priority Control Mode (PCM), select Zone or System. In an abort
condition, the Neo5 will remove power from the zone if the
malfunctioning zone is set to Zone, or go into stop mode if the
malfunctioning zone is set to System.

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Table 8-15 Advanced Settings Fields (Continued)

Item Description
AMC Automatic Manual Control (AMC) lets the Altanium automatically apply a
manual power output percentage to a heater based on a historical
average if a thermocouple fails.

Earth Leakage Check This lets you set the earth leakage check feature for each zone to ON or
OFF. The default setting is ON.

Earth Leakage Limit This limit is the threshold where Neo5 will give an Earth Leakage Alarm.
Enter the limit in Amps.

No Response Limit This is a global setting that determines how long the system should apply
96% power or more without a 5 degree rise in the temperature before it
is declared an alarm condition. The default value is 4 minutes, and the
valid range is 2 to 15 minutes.

No Heater Detected The No Heater Detected Alarm supplies immediate feedback that a
Enable heater has failed or is no longer connected to the circuit. Touch the No
Heater Detected Enable box to enable the No Heater Detected feature.

No Heater Limit This limit is used by the system to determine if a heater is still connected
to the zone. If the current measurement of the zone is below the limit for
more than 10 seconds, the No Heater Alarm will be activated.

8.7.11 Control Settings

The Control Settings drop-down tab is shown in Figure 8-36.

Figure 8-36 Control Settings

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The Control Settings fields are described in Table 8-16.

Table 8-16 Control Settings Fields

Item Description
Control Mode Set the Control Mode to Active Reasoning Technology (ART) or
Proportional Integral Derivative (PID).
ART automatically adjusts the control algorithm applicable to different
heater requirements. If a zone does not control correctly, the system you
switch from the automatically adjusted ART algorithm to an algorithm
that can be manually adjusted (PID).
Refer to Section 8.10 for information on ART and PID.

P - Proportional This is the proportional term value used by the control algorithm.
Possible values are: 0 – 250. Refer to Section 8.10.

I - Integral This is the integral term value used by the control algorithm. Possible
values are: 0 – 250. Refer to Section 8.10.

D - Derivative This is the derivative term value used by the control algorithm. Possible
values are: 0 – 250. Refer to Section 8.10.

P- ART Select this parameter to edit the P value for the selected zone in the grid.
NOTE: This setting is available only when the Control Mode value is set
to ART.

I - ART Select this parameter to edit the I value for the selected zone in the grid.
NOTE: This setting is available only when the Control Mode value is set
to ART.

D - ART Select this parameter to edit the D value for the selected zone in the grid.
NOTE: This setting is available only when the Control Mode value is set
to ART.

The P, I, and D ART parameters are used to edit the ART PID values. You can manually change
the proportional (P), integral (I) and derivative (D) values that the ART process selected. This
is used when the values the ART routine selected may not be optimal on some zones and the
user knows which values would work best without having to wait for the system to retune
those zones.

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8.7.12 ART Settings

The ART Settings drop-down tab is shown in Figure 8-37.
For information about Active Reasoning Technology (ART), refer to Section 8.10.

Figure 8-37 ART Settings

The ART settings are described in Table 8-17.

Table 8-17 ART Settings

Item Description
ART The selections are:
• Reset - This resets the ART parameters for the zones. At the next start
operation, the zones will go through the ART process.
NOTE: Reset can be selected regardless of the system mode.
• Set Flag - This tells the system that the selected zone has already
gone through the ART process and would not have to go through
the process the next time the controller is started.
NOTE: This is typically used in the Husky factory to set all zones as
having completed the ART process before your controller
ships.

ART Values Lets you view the PID values calculated by the ART process.
NOTE: The PID values for each zone are shown in this field in the format:
<P>-<I>-<D>

Output Gain Shows the output gain value returned by the control card for each zone,
after tuning is complete. Dashes are shown if the card does not return a
valid value.

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Table 8-17 ART Settings (Continued)

Item Description
Minimum P Enter the minimum Proportional (P) value

Minimum I Enter the minimum Integral (I) value.

Minimum D Enter the minimum Derivative (D) value.

Default P Enter the default P value.

Default I Enter the default I value.

Default D Enter the default D value.

ART Offset The ART Offset is the number of degrees that the actual temperature has
to be below the normal setpoint for all the zones before the system starts
the ART process.

8.7.13 Zone Follower

Some of the most vulnerable components in the mold are the thermocouples. If a
thermocouple fails, an alarm will sound, and an error is logged on the Alarm screen. When
this occurs, you can do 1 of the 3 steps that follow:
1. Stop molding, remove the mold, and repair the fault. This may not be desirable or even
possible.
2. Switch the zone to Manual control mode and continue processing. This has limitations
as Manual mode is not able to compensate for changes in the process that affect the
heater's power requirements, for example, shear heat.
3. Set the faulty zone as a follower of another zone (leader). Due to the symmetry in the
design of hot runner molds, frequently there are other zones that have very similar
thermal characteristics as the faulty zone. Neo5 can apply the power output from a fully
functioning zone to the zone with the defective thermocouple. This means that any
processing changes that affect the power requirements of the heaters are automatically
applied to the defective zone. It is similar to repairing the defective thermocouple
without ever opening the mold.

8.7.13.1 Using the Automatic Follower Function

If a thermocouple malfunctions during molding operation, the Auto-Follower function will
take over. Heaters are continuously monitored, and comparative data is stored. This data is
used to select an almost identical Leader/Follower relationship for every zone in the mold.
Based on the stored comparative data, the system knows which zone the faulty zone must
follow, so that it continues to operate in a closed loop control mode.
The only requirement is to see the error, then clear and reset the alarm. On the Neo2 View,
Multi-Group View, and Text View screens, the zone number switches between the original
zone number and the zone to which it will follow.

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Once the error is cleared and reset, the follower value is stored to the database. The Quick Set
screen for that zone shows the zone it now follows. The Automatic Follow function can be
disabled in the System Setup screen.
If the automatic follow function is unable to find a suitable partner, the Automatic Manual
Control (AMC) function is activated. If AMC is set to On, the system automatically switches the
bad zone into Manual mode applying a calculated average power output to the heater. If
AMC is Off, Priority Control Mode (PCM) is activated and shuts down either the zone or the
system based on the PCM setting.

8.7.13.2 Manually Setting One Zone as a Follower to Another Zone

If a thermocouple is about to fail, it can be set as a follower to another zone (leader) before it
fails completely.
To manually set one zone as a follower to another zone, do the steps the follow:

IMPORTANT!
Choose a leader zone with similar heater characteristics. For example, a user may not want
to set a manifold zone as a follower to a tip zone. A zone cannot be a follower to itself.

1. On the Quick Set screen, select the zones that need to be set as followers.
2. Open the Advanced Settings drop down menu.
3. Touch the box to the right of the Assign Leader Zone button. Enter the leader zone
number to which the selected zone(s) will follow, and then select the button.

On the Neo2 View, Multi-Group View, and Text View screens, the color of the manual-follower
zone changes from white to dark blue and the zone and name switches between the original
zone’s number and the zone number which it follows (leader zone).

8.8 Alarm Window

The Alarm Window lets you specify a range of how many degrees great than or less than the
Temperature Setpoint will cause an alarm. The default Alarm Window setpoint is 6 °C (10 °F).
Alarm Example: Temperature Setpoint = 300 °F, Alarm Window = 10 °F
Temperatures greater than 310 °F or less than 290 °F will cause an alarm. If the Temperature
Setpoint is changed to 350 °F, then temperatures greater than 360 °F or less than 340 °F will
cause an alarm. The Alarm Window setpoint is the same number of degrees greater than and
less than the Temperature Setpoint.
To change the Alarm Window for a zone, do the steps that follow:
1. Touch the zone to be changed.
2. Touch the Frequently Used drop-down tab.
3. Touch the Alarm Window field and enter a new value.
4. Touch the Accept button.

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8.9 Zone Calibration

To run a satisfactory injection process, temperature accuracy of the zones is important. The
Neo5 lets you make sure that your temperature readings are correct with the use of zone
calibration.
To calibrate one or more zones, do the steps that follow:
1. Make sure that all cards in the system are in place and properly secured.
2. Make sure that all card slots and access panels are covered and closed.
3. Energize the controller and let the internal temperature stabilize for at least 45 minutes.
If the controller has already been running for this amount of time you can skip this step.
4. Log into the system as administrator.
5. Make sure that the controller is in Stop mode.

6. Select the Zone Calibration button in the System Configuration group of the Neo5
Home screen

The Zone Calibration screen shows (refer to Figure 8-38).

Figure 8-38 Zone Calibration Screen

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When you open the Zone Calibration screen, the following actions occur:
• The mode changes to ‘Calibration’.
• The Start, Standby, and Boost buttons in the header become disabled.
• All zone errors become disabled until you open a different the screen.
NOTE: If you open the Zone Calibration screen in any mode other than Stop, the
buttons in the left panel will be disabled. When you stop the controller, the mode
will change to Calibration and the buttons in the left panel will be enabled again.
7. Select the zone that you want to calibrate.

8. Connect the wire harness connector to the thermocouple simulator.

The thermocouple calibrator provides a standard signal level for known temperatures (a
low temperature and high temperature).
NOTE: Refer to the thermocouple calibrator manual for installation instructions.
9. Connect the wire harness pins to the selected thermocouple connector inputs located
on the back of the controller.
Use Table 8-18 and Table 8-19 for reference.

Table 8-18 Thermocouple Color Codes

International
ANSI International IEC 584-3 American Czech Netherlands
Japanese French
Code IEC 584-3 Intrinsically Canadian British German
Safe

Table 8-19 Alloy Combination

+Lead -Lead
‡Iron Fe (magnetic) Constantan Copper -
NICKEL Cu-Ni

10. Set the thermocouple simulator to 300 °F (150 °C if the temperature units in the
controller are set to Celsius).
11. Wait about 5 seconds for the reading to be stable and then touch the Read Low button
on the left side of the Zone Calibration screen.

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12. Set the thermocouple simulator to 750 °F (400 °C if the temperature units in the
controller are set to Celsius).
13. Wait about 5 seconds for the reading to be stable and then touch the Read High button
on the left side of the Zone Calibration screen.

14. Touch the Calibrate button on the left side of the Zone Calibration screen to calculate
the simulated values and save the data for that zone to the system.

The tile button of the selected zone on the Zone Calibration screen should now show
750 °F (400 °C).
15. To do an accuracy check of the calibration, set the simulator to 500 °F (260 °C).
The tile button of the selected zone on the Zone Calibration screen should read
500 ±1 °F (260 ±1 °C) degree for the zone you have just calibrated.
16. To calibrate another zone, do the steps that follow.
a. Touch the zone tile button of the zone that you want to calibrate.
b. Connect the wire harness pins to the selected thermocouple connector inputs
located on the back of the controller.
c. Do step 10 through step 15 again.

17. When you have completed the thermocouple calibration(s), disconnect the wire
harness from the back of the controller and from the thermocouple simulator.
If necessary, you can use the Load Defaults button in the left panel to load factory default
calibration settings.

8.10 Active Reasoning Technology (ART)

Active Reasoning Technology (ART) is the science of applying microprocessor-based control

systems to automatic decision making. It is a control method directed at an active or
continuous learning process, which is tolerant to faulty functions and incorrect operation by
intentionally circumventing the incorrect operation or failure.
Active Reasoning software combined with integrated hardware disseminates information
and makes better process decisions than any modular single input, single output controller.
The ability of all zones to interact with one another and understand the effects of that
interaction is paramount. Totally automatic control is one advantage. During startup, the
control looks at all zones individually, then looks at comparisons of all zones and determines
any interaction between them. It tests for any earth leakages individually and as a whole. It
then creates the necessary bake out and soft start routines to heat the mold successfully and
evenly.

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8.10.0.1 ART Fault Handling

If an error occurs during the ART process, the Alarms screen is shown automatically, and the
error is recorded in the events log. An error stops the ART process immediately.

8.10.0.2 Altanium Card ART Process Time Limit

The control card is responsible for stopping the ART process if it has not completed within 15
minutes. The default PID values are used for zones that cannot complete the ART process,
and the ART complete flag is set.
If the ICC3 firmware does not include the time out feature, a timer will be used in the HMI. If
ART is not completed within 20 minutes, the default PID values are used for zones that did
not complete the process, and the ART complete flag is set.

8.10.0.3 ART Parameters Save and Recall

The ART parameters and completion status are included in the mold setup file. After ART is
run on a zone, the new ART parameters are automatically saved to the current mold setup file
regardless if the Auto Save Mold Setup option is enabled in the System Configuration screen.

8.10.1 Changing the Zone Control from ART to PID

The control algorithm is automatically adjusted to suit different heater requirements. This
control method is referred to as Active Reasoning Technology (ART). In some cases, it may be
necessary to switch from the automatically adjusted ART algorithm to an algorithm that can
be manually adjusted. This control method is referred to as PID. When switching a zone from
ART control to PID control, you can manually enter values for the Proportional, Integral and
Derivative parameters.

8.10.2 Typical PID Values

The following is a list of some typical PID values.

Table 8 -20 PID Values

Proportional Integral Derivative Type Example

015 010 002 Fast Probes or heaters with internally located
thermocouples
050 020 000 Fast

020 010 000 Fast

015 015 000 Fast

020 007 100 Medium Probes or heaters with internally located

thermocouples (larger mass)
020 005 200 Medium

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Table 8 -20 PID Values (Continued)

Proportional Integral Derivative Type Example

100 003 000 Slow Manifolds or heaters with externally
located thermocouples
075 003 150 Slow

8.10.2.1 Possible Causes of Oscillation

It is possible to set the control terms incorrectly, which causes an oscillation. The most
common causes of oscillation are:

Table 8 -21 Possible Causes of Oscillation

Cause Description
“P” too large Power change too great per °C of temperature change.

“I” too large Power changing too quickly for the process to follow it.

“D” too large Stepped power change too large for the rate of change of temperature.

Shear An important issue often overlooked is the effect of shear in the material as
it passes through the gating area. This can cause rises in temperature in
excess of 33 °C (60 °F) under severe conditions. Therefore, if large
temperature variations occur during molding, it is worth plotting this
variation against the molding cycle time. As the controller cannot initiate
additional cooling, it is only possible to minimize this effect with properly
selected PID terms.

8.11 ART 2.0

The use of the ART 2.0 tuning strategy gives added performance in comparison to ART
classic. With ART 2.0, the system is ready to mold much faster than before, with the
advantages that follow:
• Faster mold-tuning
• Reduced risk of tune-failure
• Reduced risk of mold-setup error
• Improved heating strategies
• Reduced dependence on local tuning skill
• Automatic zone classification
With ART 2.0, there is a shorter time to restart through improved heat-up strategies with the
potential to reduce resin degradation, which could save some material, time, and energy.
The system is able to automatically classify the type of heater that each zone controls with
the use of the ART 2.0 algorithms. In the System Setup screen, you can enter a Heater
Classification Gap that determines which zones are tips and which ones are manifolds.

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A heat capacity value, measured as zone gain in decibels (dBG), are returned by the control
card that can be used for determining the heater type. Values for all the zones are sorted in
ascending order and then the widest gap found between zones is determined. If the widest
gap exceeds the Heater Classification Gap, then the zones on the lower side of the gap are
tips and the other zones are manifolds. If no gap is wide enough, then no action can be taken
because the system cannot determine a tip from a manifold.
For typical hot runners a value of 5 dBG or 6 dBG is ideal, but there could be specialized
molding applications where these defaults are not applicable.
Figure 8-39 shows examples of how the classifications (tip/manifolds) are determined. The
gains of five zones are measured. The gains are sorted from smallest to the largest with gaps
shown between the gains. With the use of the Heater Classification Gap value that you enter
in the Tuning panel of the System Setup page, ART 2.0 counts the gaps between the
measured gains and assigns each zone a tips or manifold classification. With a Gap setting of
5, zones with lower gain measurements (and separated by 4 gaps or less) are tips, while zones
with higher gain measurements (and separated by 5 gaps or more) are Manifolds. With a Gap
setting of 6, zones with lower gain measurements (and separated by 5 gaps or less) are tips,
while zones with higher gain measurements (and separated by 6 gaps or more) are
Manifolds.

Figure 8-39 Automatic Zone Classification

A dialog window is shown after the tuning is complete for a new mold setup or if one or more
zones have been re-tuned on a different mold. This is only if the heater types have changed.
NOTE: This dialog will not show if the system cannot find a gap between zones wider than
the Heater Classification Gap setting in System Setup. The system is unable to
determine a tip from a manifold during the tuning process.
In the dialog window, the zones are shown with their determined classifications. All zones are
selected by default. If you touch the Accept button, the system will store the tips and
manifold zones that it determined. The classifications are stored in the Mold Setup for later
reference. You can also deselect or reselect zones to customize which ones are automatically
classified. If you touch the Exit button, then no automatic classification will occur.

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Chapter 9 Mold Diagnostics

Diagnostics is a useful tool for troubleshooting problems with a mold or for verifying the
wiring integrity of a mold after maintenance has been performed. You can also use
diagnostics to analyze the thermal isolation between all the cavities in the mold.

9.1 Test Settings

NOTE: The settings are set to their default values at the factory. The settings can be changed
if necessary. The steps that follow are not mandatory and only need to be done once
unless additional changes are necessary in the future.
Before you run a test you must enter in the test parameters in the Mold Test Settings screen.
To enter the settings, do the steps that follow:
1. On the Neo5 Home screen, select the Mold Test button (refer to Figure 9-1).

Figure 9-1 Quick Set Button

The Mold Test screen shows (refer to Figure 9-2).

Figure 9-2 Mold Test Screen

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2. On the Mold Test screen, select Settings button at the bottom, middle of the screen
(refer to Figure 9-3).

Figure 9-3 Mold Test Screen - Settings Button

The Mold Test Setup Screen shows (refer to Figure 9-4).

Figure 9-4 Mold Test Setup Screen

3. Touch the box to the right of the Validate Zone After button, enter the temperature in
the keypad, and then select the button.

This is the temperature rise in degrees that a zone must reach before it is considered an
operational zone.
4. Touch the box to the right of the Fixed Start Setpoint button., enter the temperature
in the keypad, and then select the button.

If the fixed setpoint is enabled, then the entered value is used as the minimum setpoint.
If not enabled, the lowest normal setpoint for the zones that are selected for testing is
used as the minimum setpoint.
All the temperatures for the input sensors that are being tested must be below this limit
before the next zone is tested during the wiring test.
5. To use the fixed setpoint, touch the checkbox to the right of the Use Fixed Setpoint
button, so a check mark shows.

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6. Touch the box to the right of the Zone Cooling Time button, enter a wait time in the
keypad, and then select the button. Refer to Section 9.2.1 for more information.

7. Touch the box to the right of the Maximum Test Time button, enter the maximum time
in the keypad, and then select the button. Refer to Section 9.2.2 for more
information.

8. Touch the Mold Test button at the bottom of the screen to return to the Mold Test
screen.

Output Power Limit button - This is a link to the Quick Set screen that lets you set an Output
Power Limit, if necessary.
Sensor button - If the zones and thermocouples are not correctly connected (zone 1 to
thermocouple 1), the box to the right of the Sensor button will become active (not greyed
out). Touch the Rewire box to correctly connect the zone to its thermocouple.

9.2 Mold Diagnostics Test

For a mold diagnostic test, do the steps that follow:

1. Before connecting any power to the controller or the mold, clean the mold and its
surroundings.

CAUTION!
Risk of damage to the equipment — Do not rely on the possibility of a ground in the
mold cables. Using a length of suitable wire, attach the mold to the mold ground
connector on the mainframe.

2. For safety, make sure that the controller and mold share the same ground.
3. Do a check of the mold wiring to make sure that there are no bare wires, frayed ends, or
cut insulation.
4. If the thermocouple(s) and power cables are present, connect them from the controller
to the mold.
5. Connect the Neo5 to the main input power and set the power to ON at the main
disconnect.
6. Log in and load a mold setup.
7. On the Neo5 Home screen, select Mold Test button.

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8. Select the desired zone(s) on the Mold Test screen.

NOTE: Only the zones selected will be tested.
9. Make sure that Neo5 is stopped.
10. If not already selected, touch the checkbox next to the test (Figure 9-5) that you want to
run on the selected zones. Refer to Section 9.2.3 for information about the tests.
Your selections are:
• Test Heaters
• Test Sensors
• Test Wiring

Figure 9-5 Mold Test Selection Checkboxes

Check marks must show in the checkboxes for the test to run.
11. Touch the Start Test button to run the test(s) on the selected zone(s).

12. If necessary, touch the Stop Test button to stop the test(s).

9.2.1 Zone Cooling Time

On some molds, it may be necessary to wait before moving on to test the next zone. This wait
time is needed in cases where, after the power has been removed, the thermocouple
continues to heat longer than expected. This is common with large manifolds. If Neo5 started
testing the next zone before the previous zone's temperature stopped increasing, this could
affect the test results. The default setting is 10 seconds. Each mold setup can have its own set
of cooling times.

9.2.2 Maximum Test Time

On some molds, if there is a thermocouple wiring problem, a heater could be damaged
during the test. Specifically, some heaters in some configurations may not support the peak
temperatures reached when full power is applied for the default test time. An extreme
example is testing a hot runner without the cavity plate in position. If the heater is large, a
short test time may not be long enough to heat up and result in a failed test. Operators can
set the maximum test time for each zone to accommodate different types of heaters. The
default setting is 2 minutes. Each mold setup can have its own set of maximum test times.

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9.2.3 Test Definitions

Test Heaters — During heating, the maximum current and voltage are recorded, and the
resistance is calculated. Also checks for blown fuses.
Test Sensor — Tests the correct functioning of the thermocouple. For example, if a
thermocouple is lost or reversed.
Test Wiring — Makes sure that the thermocouple and heaters are paired correctly (1 to 1, 2
to 2, and so on). During heating the maximum current and voltage are recorded and the
resistance is calculated. Before the cross-talk test is done, the test waits for the zone
temperature to be less than the threshold.

9.3 Mold Test Results

After a mold test has completed, you can see the results on the Mold Test Results screen.
From the Neo5 Home screen, select the Mold Test Results button.

The Mold Test Results screen shows (refer to Figure 9-6).

Figure 9-6 Mold Test Results Screen

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Table 9-1 describes the fields and buttons on the Mold Test Results screen.

Table 9-1 Mold Test Results Screen Descriptions

Item Description
Zone Zone number
Name Zone name
Senor Indicates the number of the sensor being used for that zone.
Fuses The fuses test will determine whether the fuse for that zone is operating
correctly. Fuse values are displayed as follows:
• Question Mark = Indicates the test did not complete.
• OK = Indicates the fuse for the zone passed the test.
• BLOWN = Zone failed the test and the fuse is blown.
T/C The thermocouple test will determine whether the thermocouple for
that zone is operating correctly. Thermocouple values are displayed as
follows:
• ? = Indicates the thermocouple for the zone was not tested or did
not complete the test.
• OK = Indicates the thermocouple for the zone test passed.
• REV = Reversed.
• N/C = Not Connected.
• N/A = Not Assigned.
• CAL = Not Calibrated.
• OL = Overload Positive.
• -OL = Overload Negative.
• ART = Zone is going through the ART process.
AMP Current drawn by the heater during the test for each zone.
• ? = Test did not complete.
• - - - = No current sensor for this zone.
• xx.xxA = Measured full load current of zone.
• No Heater = Measured value is less than No Heater Limit.
VAC Line voltage reading taken during the test for each zone.
• ? = Test did not complete.
• xxxV = Measured voltage being supplied to the zone.
OHMs Resistance calculated for each zone based on the line voltage and current
readings measured during the test.
• ? = Test did not complete.
• - - - = No current sensor for this zone.
• xx.xΩ = Calculated ohm value for this zone.
Watt Power calculated for each zone based on the line voltage and current
readings measured during the test.
• ? = Test did not complete.
• - - - = No current sensor for this zone.
• xxxx.xxW = Calculated full load wattage for this zone.

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Table 9-1 Mold Test Results Screen Descriptions (Continued)

Item Description
Wiring The wiring test tests for correct zone sensor assignment. This test
determines whether sensor assignments match. If a sensor assignment
does not match, the cross-talk findings test will fail.
Wiring values are displayed as follows:
• ? = Not tested or did not complete the test.
• OK = Passed.
• Fail -n = Failed where n is the zone with the maximum response.
Iso. This test calculates cross-talk data that is used to describe how well a
zone is isolated from adjacent zones. When heating one zone, adjacent
zone temperatures should not increase.
The Iso. number shown in this column identifies a cross-talk percentage
range (refer to Table 9-2).
• If an isolation value cannot be calculated, because of no heating
profile, a question mark (?) is shown for the result.
G/F The ground fault test tests for an earth leakage in each zone. Earth
leakage values are displayed as follows:
• ? = Test did not complete.
• - - - = No current sensor for this zone.
• OK = Passed.
• Fail = Failed (measured a leakage value that exceeded the Earth
Leakage Limit setting in Quick Set).
B/O The bake out test tests for moisture in each heater. Bake out values are
displayed as follows:
• ? = Test did not complete.
• - - - = No current sensor for this zone.
• OK = Passed.
• Fail = Failed (measured a leakage value that exceeded the Bake Out
Limit setting in the System Setup screen).
Leakage The measured earth leakage in amps.
• ? = Test did not complete.
Time The time it takes to test each zone.
• ? = Test did not complete.

NOTE: "Not tested", could be because the zone was not selected, or because one or two test
types (heaters, sensors, or wiring) were not checked. "Test did not complete", means
the test timed out or the user stopped the test.

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Table 9-2 shows the cross-talk percentage ranges that are identified by number in the Iso
column of the Mold Test Results screen.

Table 9-2 Cross-Talk Percentage Ranges and Isolation Rating

Iso. Number Cross-Talk Range Isolation Rating
1 81% - 100% Excellent
2 61% - 80% Good
3 41% - 60% Moderate
4 21% - 40% Fair
5 0% - 20% Poor

9.3.1 Automatic Thermocouple Wiring

Thermocouples can be inadvertently cross wired in the mold, where the thermocouple for
one heater becomes connected with another heater, and vice versa.
The Neo5 wiring test checks the thermocouple/heater wiring and determines whether the
wiring is correct. When the test is complete and if an error was found, the zone with the error
will show Failed, followed by the zone number with the maximum response in the wiring
column. Also, the Rewire button (next to Sensor) in the Mold Test Setup screen will be
enabled.
To automatically rewire thermocouples:

1. If necessary, on the bottom of the Mold Test screen, touch the Settings button.

2. On the Settings screen, touch the Rewire button to automatically reassign the mold
thermocouples to their correct zones.

NOTE: This information is saved with the current mold setup.

9.3.2 Compare Mold Test Results

You can compare a recent mold test results to a baseline mold test.
To enable this function, touch the compare checkbox on the Mold Test Results screen, so a
check mark shows.

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When the Compare function is enabled, the Mold Test Results screen will show two tables,
one above the other. The top table shows the baseline results, and the bottom table shows
the compare results. Buttons at the top of the screen lets you choose the baseline results and
compare results from a list of the tables in the database.
To see a comparison, do the steps that follow:
1. From the Mold Test screen, run a mold test (Section 9.2).
The results are stored in a diagnostics table.
2. Go to the Mold Test Results screen (Section 9.3).

3. To save the test results with a title, select the Save button in the upper right corner of
the Mold Test Results screen.

The Test Results Title keyboard will show (refer to Figure 9-7).

Figure 9-7 Test Results Title Keyboard

4. Type the Title you want to assign to the test results and select the button.

5. Touch the compare checkbox on the Mold Test Results screen, so a check mark shows.

6. Touch the Select Baseline button.

The Select Baseline dialog shows (refer to Figure 9-8).

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Figure 9-8 Select Baseline Dialog

7. Select the test that you want to use as the baseline and then select the button.
8. Touch the Select Compare button.

The Select Compare dialog shows (refer to Figure 9-9).

Figure 9-9 Select Compare Dialog

9. Select the test that you want to compare to the baseline and then select the
button.
The baseline and comparison test results are shown on the Mold Test Results screen. The
top table is the baseline test results and the bottom table is the compared test results.
The differences in amps, watts, voltage, and ohms are highlighted in red in the lower
table.
You can delete test results with the use of the Delete Result button.

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The Delete Result dialog will show (refer to Figure 9-10).

Figure 9-10 Delete Result Dialog

Select the test result you want to delete and then select the button.
NOTE: When there are 20 test results tables in the database, the Save button will be disabled.
You must delete one or more test results from the database to enable the Save
button.

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Chapter 10 Heat the Mold

This chapter describes how to start the Neo5 system and check for errors, and alarm
conditions, if they occur.

10.1 Neo5 Startup

To apply power to the zones, touch the Start button.

10.1.1 Heat Circuit Test

When you first apply power to the zones, a heater circuit test is done on all the zones before
full power is applied. The duration of this test is 15 seconds and is done before the soft start
routine (Section 10.6) is activated.
This test will detect the heater circuit faults described in Table 10-1.

Table 10-1 Heater Circuit Faults

Faults Description
Open Circuit Occurs when a conductor is broken or comes loose and no current flows
through the circuit.

Short Circuit Occurs when current travels along an unintended path as the result of a
wiring error across the heater outputs, a pair of frayed conductors, or a
pinched wire.

Leakage A low current short to ground that typically occurs when moisture is
absorbed by a heater’s insulation material.

Wrong Heater This is a case when the heater exceeds the capacity of the zone it is
connected to in the controller.

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10.2 Earth Leakage/Wet Heater Bake Out System

Neo5 is equipped with an advanced Earth Leakage/Wet Heater Bake Out system. When the
Neo5 is started, a check for earth leakage conditions on every heater is done simultaneously
and continuously. When necessary, it will start a low voltage bake out on the faulty zone(s).
This will bake the moisture out of the zones.

10.2.1 Earth Leakage Limit

For H Cards (ICC3):
The cards include a sensor specifically for monitoring leakage current in the heater circuit on
a continuous basis. The system will give an earth leakage error based on a user settable Earth
Leakage Limit with a default value of 500 milliamps and an adjustable range from 1 to 999
milliamps.
To set the Earth Leakage Limit, go to the advanced settings field in the Quick Set screen.
Refer to Section 8.7.10.

10.2.2 Configure the Length and Number of Bake Out Cycles

You can run up to 5 low-voltage bake outs, if necessary. The duration of each cycle can be set
from one to 30 minutes. The system mode and system timer indicate the progress of each
bake out cycle.
When a bake out cycle has completed, the system determines if another bake out cycle is
necessary. If the bake out alert enable parameter is active (refer to the System Setup screen,
Chapter 11), and, after the set number of bake out cycles are completed, if there is still
enough moisture in the system to warrant another bake out cycle, the system will
automatically shut down and trigger a bake out alarm. If there is no more moisture in the
system after the set number of bake out cycles have completed, the soft start process will
begin.
The system will declare a bake out error based on a user settable Bake Out Limit with a default
value of 200 milliamps and an adjustable range from 1 to 999 milliamps. Any value of 200
milliamps or higher, but lower than the earth leakage limit, will trigger a bake out error.
Refer to the System Setup screen, Chapter 11, to set the Bake Out parameters.

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10.3 AltaStart

The AltaStart function is used for heat sequencing. This system analyzes the likely heat-up
time of tip zones and scheduling each one to make sure that they get to their respective
temperature setpoints within 3 minutes of the manifolds. When AltaStart is used:
• Zones that are turned OFF will not be included in the AltaStart process.
• Zones in manual regulation will use a scaled power value during the AltaStart process,
similar to soft start.
• The Heater Type setting must be set to Tip or Tips before the AltaStart process will work.
• The tips zone must wait at least 180 seconds (3 minutes) before determining when to
start heating. This is done in case the manifold zones become power saturated and it
takes longer for them to heat up.

10.4 UniStart

The UniStart function provides the shortest start-up time while ensuring that all
temperatures track to their setpoint.
NOTE: If AltaStart is enabled, only non-tip zones will be included in the UniStart process. If
AltaStart is not enabled, then all zones will be included in the UniStart process.
When the Neo5 Start button is select, the system operates as follows:
1. Fast heating is applied if enabled. Refer to Section 10.5.
2. The lowest common Integral value (of PID) between all the zones is determined and is
shared with the other zones.
3. The global ramp limit is shared with all of the zones.
4. The zones in the UniStart process will no longer use the Ramp Limit or common Integral
when they enter the At Temperature window (refer to Section 8.8). The previous Integral
value will be restored.
The system also does a check for power saturation during the heat process:
• If some zones have power that is within 4% of the present power limit (the same
threshold as No-Response), it will be considered saturated. The zone with the smallest
delta from the limit will be the lead zone.
• The present ramp of the UniStart group’s lead zone should be shared among all of the
zones in the group. This sharing is similar to that of sharing the Integral except that the
value is likely to change while heating. This value will persist for as long as the zone is
under UniStart control. As zones enter At-Temperature, all limits are lifted.

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10.5 Fast Heating

The UniStart process heats the zones slowly, but evenly. When Fast Heating feature is
enabled, the system pushes some zones to heat faster, as follows:
• The system looks at all the zones to see if the Integral value (of PID) is less than 2. If it is,
then the value is changed to the lesser of either:
• Twice its normal value, or a maximum value of 2.
• The Proportional (of PID) is then multiplied by a fraction. The fraction is the old
Integral value divided by the new Integral value.
Example 1: A zone’s ART PID values are 15.0, 1.2, and 1.4. The system will change the
integral value to 2 and multiply the proportional value by 1.2 / 2 or 0.6.
Then 15 x 0.6 = 9. The new PID values then become 9.0, 2.0, and 1.4.
Example 2: A zone’s ART PID values are 15.0, 0.6, and 1.4. The system will change the
integral value to 1.2 and multiply the proportional value by 0.6 / 1.2 or 0.5.
Then 15 x 0.5 = 7.5. The new PID values then become 7.5, 1.2, and 1.4.

• The new values (P and I) will be used until the zone’s temperature reaches the At
Temperature window. The P and I values will then be restored to their original values.
• This feature only applies to zones that are using ART PIDs.
• The Fast Heating Enable setting is saved to the mold setup. The default value is selected.

10.6 Soft Start Routine

During the soft start routine, all the zones warm up simultaneously, and at the same rate. The
soft start routine results in even thermal expansion and identical residence time on the
material.
NOTE: Soft start is not active during staged startup.
The soft start sequence shown in the steps that follow:
1. If necessary, the bake out starts.
NOTE: If the ART process has not been completed, the ART Process screen will show
when starting soft start.
2. The ART process begins if it has not already run.
3. "Soft Start" is shown in the status bar. The power applied to the heaters varies from the
probes to the manifold zones, the probes receiving less power and the manifolds
receiving more. All of the zones increase in temperature at the same rate to ensure a
smooth even thermal transfer within the mold. This helps to eliminate mold leakage.
4. When all temperatures are near their setpoint, "Running" is shown in the system mode.

NOTE: You enable Soft Start on the System Setup screen (refer to Chapter 11).

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10.6.1 Adjusting the Soft Start Minimum Limit

The soft start limit is used to calculate the window between the lowest temperature zone and
the highest temperature zone in the system. This window is maintained throughout the soft
start process and determines the gap between the coldest and hottest zones. Generally,
lowering the soft start limit value decreases this gap, contributing to greater thermal
uniformity of the hot runner system from a cold startup.
To set the soft start minimum limit, refer to the System Setup screen (refer to Chapter 11).

10.7 Alarm Screen

The Alarm screen shows the errors that occur (refer to Figure 10-1). When an alarm is active,
an icon on the Alarm button in the system footer changes to yellow and flashes red.
NOTE: For a description of the alarm conditions displayed on the Event History screen and
Alarm screen, refer to Section 10.9. For a description of the abort conditions displayed
on the Event History screen and Alarm screen, refer to Section 10.10.

Figure 10-1 Alarm Screen

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Table 10-2 describes the items on the Alarm screen.

Table 10-2 Alarm Screen Descriptions

Item Description
Date/Time Date and time that the alarm was triggered.

Source Cause of the alarm.

Description Description of the problem that triggered the alarm.

Near the top right corner of the screen, there is a quick link button to the Event History
screen.

The Event History screen stores all the alarms after they have been cleared from the Alarm
screen.

10.7.1 Opening the Alarm Screen

There are two buttons you can use to show the Alarm screen:
• Alarms button in the Data Collection and Monitoring group of the Neo5 Home screen
(refer to Figure 10-2).

Figure 10-2 Alarms Button

• Alarm Status button in the system footer on all screens (refer to Figure 10-3).

Figure 10-3 Alarm Status Button

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10.7.2 Clearing Alarms

If an error occurs, Neo5 will turn on audible and visual alarms and show the alarm condition
on the Alarm screen.
To clear an alarm, do the following:

To silence an audible alarm, touch the Silence Horn button.

To reset the alarm light and acknowledge the alarm, touch the Alarm Reset button.

NOTE: Before you reset an alarm, correct the source of the alarm.
Touch Alarm Reset button once and the alarm is assigned the inactive/not acknowledge
state.

Touch Alarm Reset button twice and the alarm is assigned the inactive acknowledge state.
This clears the alarm from the screen. You can see the alarm in the Event History screen after
the alarm is cleared.

10.8 Event History Screen

The Event History screen lists the zone alarms, alarms, warnings, setpoint changes, setup
changes, HMI startup, and out of specification events that have occurred previously (refer to
Figure 10-4).

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Figure 10-4 Event History Screen

On the Neo5 Home screen, touch Event History button to see the Event History screen (refer
to Figure 10-5).

Figure 10-5 Event History Button

NOTE: For a description of the alarm conditions displayed on the Event History screen and
Alarm screen, refer to Section 10.9. For a description of the abort conditions displayed
on the Event History screen and Alarm screen, refer to Section 10.10.
Table 10-3 describes the items on the Event History screen.

Table 10-3 Event History Screen Descriptions

Item Description
Date/Time Date and time that the event was triggered.

Source Where the event occurred.

Event Name of the event.

Mold Indicates the mold that is associated with the mold setup that was
loaded when the event occurred.

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Table 10-3 Event History Screen Descriptions (Continued)

Item Description
Mold Setup Indicates the mold setup that was loaded when the event occurred.

Details Describes the event.

10.8.1 Filtering Events

On the Event History screen, you can filter the events you want to see. One or more event
types can be selected, and you can filter by dates. Do the steps that follow to select the events
that will show:
1. On the Event History screen, touch the Filter button.

2. In the Filter Events dialog the shows (Figure 10-6), select the event types that you want
to see.

3. Touch the button.

Figure 10-6 Filter Events Screen

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10.9 Alarm Conditions — Warning Errors

Alarm conditions are displayed on the Alarm screen and the Event History screen. The
conditions shown in Table 10 -4 cause the audible and visual alarms to initiate. Because they
are warnings, they will not shut any part of the system down.

Table 10 -4 Warning Errors

Warning Description
Alarm Over Temp A zone's actual temperature has exceeded its setpoint by the
amount set for the alarm limit.

Alarm Under Temp A zone's actual temperature has dropped below its setpoint by
the amount set for the alarm limit.

Auto Following Enabled A zone has had its thermocouple become defective while
running in automatic control mode. The system sets this zone to
follow another zone using data it collected before the
thermocouple became faulty. The faulty zone is now being
controlled by the power output from another similar zone. The
leader zone number will be shown in the Assign Leader Zone
box of the faulty zone in the Quick Set screen.

AMC Active A zone has had its thermocouple become defective while
running in automatic control mode. There was no match found
for this zone in the mold by the Auto-Follow feature or the Auto-
Follow feature is turned off. The zone has been setup to go into
Automatic Manual Control (AMC) in this event. The zone is now
being controlled in manual mode at a power percentage
selected by the controller using data it collected before the
thermocouple became faulty.

Power Deviation The zone’s power output value has deviated by an amount
calculated by the power deviation algorithm. The power
deviation algorithm is based on several factors, including a
historical power average, heater type, changes to the power
supplied to the unit, etc.

No Heater Instantaneous feedback that a heater has failed or is no longer

connected to the circuit. The zones current draw was below the,
no heater detection limit, for more than 10 seconds.

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10.10 Abort Conditions — Shutdown Errors

Abort conditions are displayed on the Alarm screen and the Event History screen. The
conditions in Table 10 -5 initiate the audible and visual alarms. Since they are shut down
errors, they will cause a zone or system shut down situation based on the PCM setting.

Table 10 -5 Shutdown Errors

Shut Down Error Description

Abort Over Temp A zone's actual temperature has exceeded its setpoint by the
amount set for the abort limit.

Abort Under Temp A zone's actual temperature has dropped below its setpoint by
the amount set for the abort limit.

Circuit Overload The over current hardware signal is triggered by the current
sensor. This error occurs immediately: usually in a dead short
situation.

Control Card Over Temperature A control card temperature has exceeded 76 °C (170 °F).

Earth Leakage ICC2: If the calculated limit or default value is exceeded, the earth
leakage error is triggered.

ICC3: If the measured leakage level exceeds the Earth Leakage

Fault Limit value, the earth leakage error is triggered.

Fuse 1 Blown Fuse 1 on this Intelligent Control Card (ICC2 or ICC3) has blown
and needs replacing.

Fuse 2 Blown Fuse 2 on this ICC2 or ICC3 has blown and needs replacing.

Line Impedance No line voltage was determined by the control card.

• During Circuit Test the controller is monitoring large sifts in
voltage.
• An alarm is triggered if there is a shift greater than 6 volts at
3% duty cycle.
• This alarm can only be raised during Circuit Test.

Lost Thermocouple This zone has a defective or open thermocouple.

Maximum Temp Limit The temperature on this zone has risen above the maximum
value allowed. This usually means the switching device has failed
in the closed position and the zone ran away. The factory setting
is 95 °C (200 °F) over the normal setpoint.

No Response The system has been applying 96% to 100% power to this heater
for a set amount of time, and the thermocouple connected to this
zone is not responding. The thermocouple may be pinched, or
the heater power wires may be broken.

Over Current Limit The current on this zone has risen above the maximum value
allowed.

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Table 10 -5 Shutdown Errors (Continued)

Shut Down Error Description

Over Voltage The A/C voltage read by the control card is greater than 280 VAC.
• 280 volts is the highest level of voltage the control cards can
withstand before permanent damage occurs.
• This alarm can be triggered at anytime the controller is in
Start mode.

Receive Data Comm This zone has stopped receiving data.

Rev. Thermocouple The positive and negative leads from the thermocouple have
been switched or the connections are reversed. As power is
applied, the temperature goes down instead of up. Correct this
situation at the point where the wires are reversed.

Read Time Out This zone has stopped transmitting data.

Under Voltage The A/C voltage read by the control card is lower than 170 VAC.
• 170 volts is the lowest level of voltage the control cards can
receive and still function properly.
• This alarm can be triggered at anytime the controller is in
Start mode.

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Chapter 11 System Setup Screen

This chapter describes the functionality available in the System Setup screen, and provides
instructions on setting some of the most commonly used system wide preferences.

11.1 System Setup Screen

Use the System Setup screen to configure the Neo5 system.
To see the System Setup screen, touch System Setup button on the Neo5 Home screen (refer
to Figure 11-1). The System Setup screen shows (refer to Figure 11-2).

Figure 11-1 System Setup Button

You can also use the System Setup button in the header of all other screens.

Items in this screen depend on the access rights of the user and the current state of the
system.
Table 11 -1 describes the setting items on the System Setup screen.

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Figure 11-2 System Setup Screen (Composite)

Table 11 -1 System Setup Screen Item Descriptions

Item Description
Serial Number The Serial Number is for informational purposes only. It is a
number assigned to the system when it is manufactured. Husky
support may ask for this number when troubleshooting or
upgrading.

Model Controller model name.

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Table 11 -1 System Setup Screen Item Descriptions (Continued)

Item Description
SOM Model This field displays the model of the System On Module (SOM)
installed in the controller.

Company Name User definable company name displayed in the system header.

Software Version The Current Software Version is for informational purposes only.
Husky support may ask for this number when troubleshooting or
upgrading.

Auto Save Mold Setup If checked, all changes to the current mold setup will be saved as
they occur and cannot be discarded.

Quick Adjustment Enable Enables the Quick Adjustment panel (refer to Section 8.6).

Time Zone Used to set your time zone.

Allow Monitor Regulation for Enables the parameter that allows the change of the regulation
Selection mode to “Monitor” for zones in the Quick Set screen.

Exclude Monitor Zones from Enables the parameter that allows the exclusion of the zones set
At-Temperature to “Monitor” regulation from the at-temperature determination
by the system.

Force Phase Angle Control There are two methods for controlling the power applied to the
heaters, refer to Section 2.2. If checked, only the phase angle
control will be used.

Show Temperature For A global setting that controls whether the controller view screens
Manual Zones display the thermocouple readings for zones in manual mode.
Same Sensor Input Max Limit Used to set the maximum limit for a sensor input. If you try to
assign the same value to the "Sensor Input" setting in the Quick
Set screen, and it is more than the "Same Sensor Input Max Limit",
a dialog will show that alerts you that the change cannot be made
with an explanation why. The range is 1 to the number of
configured zones in the system. The default value is 2.

Global Output Power Limit Controls the maximum output power delivered to each zone.
Overrides the individual zone setting in the Quick Set screen.

Force Temperature Units to Forces the temperature units to specified settings.

Wattage Voltage Insert the designed voltage rating of the heaters so the system can
accurately calculate Watt Voltage.

Supply Configuration Used to select the supply configuration parameter: Delta 3PH,
Wye 3PH+N, Single Phase, or Integrated Tx.

Voltage Regulation Enables voltage regulation.

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Table 11 -1 System Setup Screen Item Descriptions (Continued)

Item Description
Diagnostics Export Used to generate and export a zip file with files that help
troubleshoot problems that occur with the system or the mold.
The files contained in the zip file are:
• Detailed Zone Information
• Event History Log
• Power Deviation Data
• Process Monitoring Data
• Current Mold Setup
• Additional directory that contains diagnostic data for Husky
software engineers

Software Package Information Used to see the software packages installed on your system.

Tuning Strategy Used to select the ART Classic or ART 2.0 tuning strategy. ART 2.0
is selected by default. Refer to Section 8.10 and Section 8.11 for
more information.

Heater Classification Gap Used to specify the gap that is used to determine where tip zones
end and where manifold zones begin. The range is 1 to 9.9 dBG
and the default value is 6 dBG. Refer to Section 8.11 for
information on this setting.

AltaStart Enable Used to enable AltaStart function for heat sequencing. Refer to
Section 10.3.
NOTE: At least one zone’s heater type must be set to ‘Tips’ or the
system will not allow you to enable the function.

Heat Uniformity Method Lets you select the heat uniformity method you want to use:.
• UniStart - When selected, this provides the shortest start-up
time while ensuring that all temperatures track to their
setpoint. Refer to Section 9.4.
• Soft Start - When selected, the soft start process is applied
upon startup. Refer to Section 9.6.
• None
The default value is UniStart. Only the settings that are specific to
the method selected will be enabled. For example, if UniStart is
selected then all the Soft Start settings will be disabled. This
setting is saved to the mold setup.

Global Ramp Limit This setting is applied to all zones in the UniStart process. It is the
rate at which temperature will increase per minute as it heats to
the setpoint. The valid range is 9 °F to 180 °F (5 °C to 100 °C). The
default value will be 180 °F (100 °C). This setting is saved to the
mold setup.

Fast Heating Enable Enables the Fast Heating function (refer to Section 9.5).

Dynamic Soft Start Enable If checked, the dynamic soft start is enabled.

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Table 11 -1 System Setup Screen Item Descriptions (Continued)

Item Description
Soft Start to ART Setpoint When enabled, the soft start routine is used when heating zones
Enable to the tuning setpoint during the ART process.

Soft Start Minimum Limit Once the soft start process is initiated, the system calculates the
difference between the zone with the highest and lowest
temperatures. If this difference is less than this parameter value,
then this parameter value is applied to the soft start process.

Minimum Limit Defines the minimum threshold for activating the AT-
Temperature signal. The AT-Temperature signal goes active when
all active zone temperatures are within the lower alarm limit. If the
alarm band setting is smaller than the AT-Temperature Minimum
Limit, then the AT-Temperature Minimum Limit is used to activate
the AT-Temperature signal.

Delay Timer Enable The delay timer will start, if checked.

Delay Timer Sets the amount of time the system will wait before the AT-
Temperature output signal is activated.

Delay Timer Status Time remaining on the delay timer.

Audible Notification Enable Will give an audible notification that the zones are at temperature.

Audible Notification Interval The time between the audible beeps.

Auto Following Enable Toggle this parameter on or off.

Auto Following Power Limit This value is the limit used by the Auto Following routine to
determine if the average power output of a candidate zone is
within the acceptable deviation of the following zone.

License Number Shows the license number of the Neo5 software installed on your
system.

Import Settings Used to import default setting screen values. The button is
enabled if a USB drive is plugged into the USB port and the current
user has the proper permission level.

Export Settings Used to export default setting screen values. The button is
enabled if a USB drive is plugged into the USB port and the current
user has the proper permission level.

Alarm Sensitivity The duration of time the system has to stay in an error condition
before it is declared an alarm.

Maximum Temperature Limit The number of degrees over the setpoint the Maximum
Temperature Alarm is activated.

Over Current Enable If checked, the Over Current alarm is enabled.

Earth Leakage Fault Enable Toggle this parameter to turn earth leakage checking on or off.

Display Earth Leakage Reading Enables the Leakage column in the Text View screen.

Circuit Test Enable Enables the circuit test for ICC3 cards.

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Table 11 -1 System Setup Screen Item Descriptions (Continued)

Item Description
Auto Power Limiting Enable If checked, the Auto Power Limiting feature is enabled.

Circuit Test State 4 Power Determines the power percentage applied during circuit test
Level state 4.

Bake Out Enable If this parameter is enabled, the system will run the bake out test
and apply a low voltage to remove the moisture in a heater if
required. Toggle this parameter on or off.

Force Bake Out Enable Toggle this parameter on or off. If this parameter is on, each zone
in the system is baked out upon startup.

Bake Out Alert Enable If this parameter is enabled, the system stops and generates an
alarm for each zone with a bake-out condition that has not been
cleared during the bake out cycle.
If this parameter is disabled, the system exits the existing bake-out
cycle and continues the startup sequence.

Bake Out Limit The system uses this value to assess whether a bake-out condition
exists. Upon system startup, if any zone exceeds this limit, the
system will enter bake-out mode.
For ICC2 cards, the parameter range is 0 to 5 amps. The default
value is 0.2 amps.
For ICC3 cards, the parameter range is 1 to 999 milliamps. The
default value is 200 milliamps.

Bake Out Power The system uses this value during the bake out process.
The parameter range is 1 to 25%. The default value is 5%.

Bake Out Time Per Cycle Length of the bake out cycle. The parameter range is 1 to 30
minutes. The default value is 5 minutes.

Number of Bake Out Cycles The number of attempts to bake out the moisture in a heater. The
parameter range is 1 to 10. The default value is 1.

Bake Out Setpoint Specifies the bake out setpoint the zones must achieve during the
bake out process. The default value is 100°C (212°F). Displays only
if ICC3 cards are installed.

At Bake Out Temperature During the bake out process, this parameter specifies the
Window threshold that all zones must achieve before the bake out cycle
value starts counting down. The default value is 5°C (9°F). Displays
only if ICC3 cards are installed.

Heat to Bake Out Setpoint Specifies the amount of time the zones are given to achieve the
Timeout bake out setpoint. If the time period expires, a warning message
displays the problem and what happens when the warning
message is acknowledged. Displays only if ICC3 cards are installed.

Use Advanced Functionality When enabled, this toggles the system from Basic to Advanced
functionality.

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Table 11 -1 System Setup Screen Item Descriptions (Continued)

Item Description
Import Settings Used to import Customize screen setting values. The button is
enabled if a USB drive is plugged into the USB port and the current
user has the proper permission level.

Export Settings Used to export Customize screen setting values. The button is
enabled if a USB drive is plugged into the USB port and the current
user has the proper permission level.

11.2 Changing the Number of Zones in the System

You may need to add or remove zones to an existing mold setup. If the mold running has
fewer control zones than listed on the screen, you can remove the unused zones to make
sure they are not displayed.
To change the number of zones in the system, do the following:

1. On the Neo5 Home screen, select the Zone Slot Config button (refer to Figure 11-3).

Figure 11-3 Zone Slot Configuration Button

2. On the Zone Slot Configuration screen (Figure 11-4), select the number of zones and/or
slots to be enabled or disabled.

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Figure 11-4 Zone Slot Configuration Screen

3. Touch the Slot Enable button.

4. Touch the Enable or Disable button in the Slot Enable selection dialog.
5. Touch the button.
6. Restart the controller.

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Chapter 12 Staged Startup and Shutdown

This feature allows the Neo5 to heat or cool zones in a predetermined order by using stages.
Zones can be assigned to any of the four stages and can be configured with a separate set
point for each stage. A timer can also be configured for each stage which will allow all the
zones to "soak" for a defined amount of time. The hot runner system must be heated (Staged
Startup) and cooled (Staged Shutdown) in a specific order to prevent problems such as
misalignment and leaking.

12.1 Enabling or Disabling Staged Startup

To enable or disable selected for staged startup, do the steps that follow:
1. On the Neo5 Home screen, in the Temperature Management group, select the Staging
button.

The Staging screen shows (refer to Figure 12-1).

Figure 12-1 Staging Screen

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2. On the Staging screen, select the zones or groups that will be included in Stage x
Startup.
NOTE: x = 1, 2, 3, or 4.
3. Touch the Staged Startup button to show the drop-down menu.

The Staged Startup drop-down menu shows (refer to Figure 12-2).

Figure 12-2 Staged Startup Drop-Down Menu

4. Touch the checkbox next to the Enable button, so a check mark shows.
The staged startup is enabled.
5. To disable staged startup, touch the check box again, so the check mark does not show.
The staged startup is disabled.
Table 12-1 describes the settings in the Staged Startup drop-down list.

Table 12-1 Staged Startup Drop-Down List Descriptions

Item Description
Run Last Stage Indefinitely If this setting is enabled, all zones in the last assigned stage will
not change to their normal setpoint once all zones have achieved
the stage setpoint and the soak timer has expired.

Stage x Soak Timer The time the zones stay “soak” at the stage setpoint before the
next stage begins.

At Temp Window The stage will be At Temperature when the setpoint is within the
At Temperature window.

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12.2 Setting Soak Timers

At the end of each stage during staged startup or shutdown, when all the zones are at the
stage setpoint, they can be left to "soak" for a specified time before the next stage begins. Use
the Staging screen to change the soak time lengths.
NOTE: It is not necessary to assign a soak time to each stage. To avoid a delay between when
a stage has reached setpoint and before the following stage is activated, set the timer
to 00:00:00.
NOTE: It is not necessary to select zones to set the soak timer.
1. On the Staging screen, touch the Staged Startup button to show the drop-down menu.
2. Touch the button to the right of the Stage 1 Soak Timer bar (refer to Figure 12-2).
3. Use the dialog box to enter the soak time in the dialog (Figure 12-3), and then select the
button.

Figure 12-3 Startup Stage 1 Soak Timer

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12.3 Set the Stage Temperature and Power

1. On the Staging screen, select the Stage x (Startup) button to show the drop-down
menu (refer to Figure 12-4).
NOTE: x = 1, 2, 3, or 4.

Figure 12-4 Stage 1 (Startup) Drop-Down Menu

2. Touch the button to the right of the Stage x Temperature bar.

3. In the dialog box, enter the temperature for Stage x, and then select the button.

4. Touch the button to the right of the Stage x Power bar.

5. In the dialog box, enter the percentage of power for Stage x, and then select the
button.

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Chapter 13 Data Recording

Data Recording is a useful tool to track the operation of a mold. This tool helps analyze the
system to optimize the molding process, track errors, find the source of a recent error or
predict where future errors may occur. The Error Log contains a record of errors that have
occurred since the errors were last cleared. Use the Process Monitoring screen to view the
operation of a mold and view recorded data. If an error has occurred while the system was
recording, review the behavior of the system at the time of the error to search for potential
causes.

13.1 Process Monitor Screen

To see the Process Monitor screen, select the Process Monitor button in the Data Collection
and Monitoring group of the Neo5 Home screen.

The Process Monitor screen shows two graphs. You can plot 1, 2, or 3 parameters on each
graph for the selected zone. The parameter plots are color coded. The x-axis is the parameter
and the y-axis is the time. There is also a checkbox that lets you share the scale between the
two graphs.

Figure 13-1 Process Monitor Screen

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13.1.1 Change the Zones

You can change the zones shown in the graphic charts with the steps that follow:
1. Touch the box to the right of the Zone bar.
2. Use the keypad and enter the new zone number and then touch the button.

13.1.2 Change the Graphic Process Traces

You can change the trace parameters that are shown in the graphic charts on the Process
Monitor screen. The parameter selections are:
• Setpoint
• Temperature
• Power
• Amps
• Leakage
• Volts
• None
To change a parameter, do the steps that follow:
1. Touch the number 1 (green) parameter box.
A select plot parameter dialog shows (refer to Figure 13-2).

Figure 13-2 Select Parameter Dialog

2. In the dialog box, select the parameter that you want to see plotted on the chart and
then touch the button.

3. Do step 1and step 2 again for the number 2 (yellow) and number 3 (blue) parameters.

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13.1.3 View a Specific Point on the Plot

When you start the Neo5, the parameters for the selected zone will start to plot on the graph.
You can select a point on the chart to see the data values recorded for a specific time on the
plot. Do the steps that follow to select a point in time:
1. Touch an area in the chart that’s close to the point in time that you want to see.
The chart cursor (dashed vertical line) moves to that spot.
2. Use the left arrow and right arrow buttons to move the cursor to the data point on the
chart that you want to see. The value of the parameter(s) at that point will show in the
box next to the parameter name(s), and the time will show in the box to the right of the
arrow buttons.

13.2 Power Deviation

When enabled, the Neo5 can let you know when the power output percentage on a zone
deviates a specified amount while it is running under normal conditions. This could be useful
to detect plastic leaks in the gate area or manifold pocket.
NOTE: Leaks may not be detected if large amounts of plastic are injected into a mold.
With the use of the configured settings, the system uses an algorithm to learn a power
baseline. The power deviation algorithm will generate an alarm for classified zones if the
power has deviated from the baseline.
Power deviation should only be used with the conditions that follow:
• The mold is installed in the machine with cooling ON.
• The ART process has completed successfully, and you have made sure you have a stable
process.
Select the Power Deviation button to see the screen (refer to Figure 13-3).

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Figure 13-3 Power Deviation Screen

Table 13-1 describes the information shown on the Power Deviation screen.

Table 13-1 Power Deviation Screen Information

Item Description
Zone Shows the zone number.

Name Shows the assigned zone name.

Heater Type Shows the type of heater used.

Status Shows the current status of the algorithm:

• No Baseline – A baseline has not been established by the algorithm
• Active – A baseline has been established by the algorithm
• Not Active – The zone is not participating in the algorithm. This
means that the zone is OFF.

Learned Baseline Shows the learned baseline power percentage.

± Tolerance Shows the calculated tolerance limit that the algorithm uses to
determine when an error is generated.

Deviation Shows how much the current power average has deviated from the
baseline.

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13.2.1 Configure the Power Deviation

To use the process deviation application, do the steps that follow:
1. Select the Quick Set button on the Neo5 Home screen.

2. Select Heater Types on the Quick Set screen (refer to Figure 13-4).

Figure 13-4 Heater Types

3. Assign a custom label for up to 8 heater types (refer to Section 8.7.9).

NOTE: The controller must be in Stop mode for these fields to be active.
4. Assign all tip zones to a group (refer to Section 8.7.9).
NOTE: If all of the tip zones use the same heater (based on the number of heaters per
zone, design Voltage, and wattage) then they should be assigned to the same
Heater Type group. There should be as many Heater Type groups assigned as
there are different tip heaters in the mold (based on the number of heaters per
zone, design Voltage and wattage).
5. Select the Power Deviation button on the Neo5 Home screen.

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6. Select the Setup button at the bottom left corner of the screen.

The Power Deviation Setup dialog shows (refer to Figure 13-5).

Figure 13-5 Power Deviation Setup Dialog

Table 13-2 describes the settings on the Power Deviation Setup dialog.

Table 13-2 Power Deviation Setup Dialog Settings

Item Description
Power Deviation Used to enable the Power Deviation feature.
Enable

Use Auto Calculated This setting lets you determine if the tolerance value calculated by the
Tolerance algorithm should be used or if the user specified tolerance should be
used.

Sample Period This is the period of time that the algorithm uses to gather power
samples for learning the baseline and for monitoring the current power
values. This field is adjustable from 30 seconds to 1 hour and the default
value is 15 minutes.

Stabilization Time This is the period of time the algorithm waits after all zones are within 5°F
of setpoint before starting to learn the baseline or for monitoring the
current power values. This field is adjustable from 30 seconds to 1 hour
and the default value is 2 minutes.

Learning Minimum A lower limit used when calculating the relative tolerance. The calculated
Limit value cannot be lower than this limit. It is adjustable from 2 to 75% and
the default value is 10%.

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Table 13-2 Power Deviation Setup Dialog Settings (Continued)

Item Description
User Specified If you do not want to use the calculated value determined by the
Tolerance algorithm, then this value can be used instead. You must also un-check
the ‘Use Auto Calculated Tolerance’ setting and then specify the value
that you want. This setting is adjustable from 2 to 75% and the default
value is 10%.

Relearn Button This button is used to force the power deviation algorithm to learn the
baseline for all classified zones again. When the button is pressed, the
power deviation status field should change to ‘Learning’ and all previous
baseline information should be cleared.

7. Touch the Power Deviation Enable check box to enable the power deviation feature.
8. Touch the Use Auto Calculated Tolerance check box to enable this feature.
9. Set the Sample Period to 15 minutes.
10. Set the Stabilization Time to 2 minutes.
11. Set the Learning Minimum Limit to 10%.
12. Do not change the User Specified Tolerance.
NOTE: With the Use Auto Calculated Tolerance enabled, the system will calculate this
value.

13. Touch the button to exit the Power Deviation Setup dialog.

Use settings that work best for your process. If you do not want to use the auto calculated
tolerance, you can disable that feature, enter the settings that you want, and then select the
Relearn Baseline button.

13.2.2 Troubleshooting
When a power deviation is reported, you can troubleshoot the issue from the Power
Deviation screen. Touch the View Troubleshooting Data circle at the top of the screen (refer
to ). Additional information for the zones is given to help diagnose problems with the
algorithm.
NOTE: This screen is only accessible by Neo5 system Administrators.

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Figure 13-6 Troubleshooting Data Screen

13.3 CAN Information

The CAN Info screen is used for troubleshooting communication issues on the Controller
Area Network (CAN) bus. The CAN field bus used to communicate between the control cards
and the HMI. Husky Support will instruct you on the use of the screen, should communication
issues arise.
Table 13-3 describes the values on the CAN Information screen.

Table 13-3 CAN Information Screen Descriptions

Item Description
Zone Shows the zone number.

Setpoint Shows the temperature setpoint.

SPwr Shows the setpoint power percentage.

This is the setpoint assigned to each zone when they are set to manual
regulation.

Temp Shows the zone temperature.

Pwr Shows the percentage of power used to heat the zone.

Amps Shows the amps used to heat the zone.

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Table 13-3 CAN Information Screen Descriptions (Continued)

Item Description
Avg Shows the average power output percentage.
This is used by Auto Following.

Sen This is the sensor number assigned to the zone.

The sensor is assigned in the Quick Set screen.

Status Shows the error status for the zone.

A number value is given that identifies the zone error.

Reg Shows the regulation mode (Auto, Manual, or Monitor).

Mode Shows the operation mode (Run, Off, Stop, Standby, Boost, and so on).

Follower Shows which zone a faulty zone will follow.

If a thermocouple is about to fail, it can be set as a follower to another
zone (leader) before it fails completely.

Volts Shows the volts set for the zone.

BdTemp Shows the board temperature.

This is the temperature of the Intelligent Control Card (ICC).
The temperature sensor is built into the card.

Rst This counts the number of CAN controller resets.

CAN Counts the number of CAN messages per second.

Osc Shows the number of faults on the CAN oscillator chip on the control
card.

CAN Id Shows the CAN Identification assigned to each zone (slot) on the control
card.

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Chapter 14 Data Exchange

You can store reports and images to the Neo5 hard drive. From the file management screen,
you can move the reports and images to a network or USB device for sharing, storing, or
printing. Or you can save directly to the USB device or network.

14.1 Select Reports, Process Data, and Settings

To see the Data Exchange screen, select the Data Exchange button in the Data Collection
and Monitoring area of the Neo5 Home screen.

The Data Exchange screen shows (refer to Figure 14-1).

Figure 14-1 Data Exchange Screen

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On the Data Exchange screen, select the reports that you want to save (refer to Table 14-1).

Table 14-1 Report Selections

Item Description
Select Report Type Put a check mark in the checkbox next to the report that you want
to save. Refer to Table 14-2 for descriptions of the reports.

Save Report Data To Put a check in the box next to where you want to save the report.
A USB Device must be installed in the USB port or the Neo5 must
be connected to a network. Use the Folder Search button to select
a folder in which the file is stored.

Save Process Data Setup Check the save data to File box to save the process data to the
Neo5 hard drive. Touch the Frequency button and enter in the
time intervals that you want Neo5 to save the current process
data. Touch the Select Process Variables button and put a check
mark next to the process variables that you want to save.

The data log records as follows:

• Data is collected every 1 second and stored in a circular
buffer.
• The circular buffer is overwritten every 10 minutes.
• The data is pulled from the buffer and stored to a file every 5
seconds, or to whatever time the Frequency is set.

Save Process Data To Put a check in the box next to where you want to save the process
data. A USB device must be installed in the USB port, or the Neo5
must be connected to a network. Use the Folder Search button to
select a folder in which the file is stored.

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Table 14-1 Report Selections (Continued)

Item Description
Networking With the Interface Configuration settings, you select Static or
dynamic (DHCP) property values:
• Static settings:
- IP Address
- Subnet Mask
- Default Gateway
• DHCP setting:
- IP Address
Use the gear button next to Interface Configuration to access the
settings.

With the Network Share settings, you can enter the network path
for the shared network folder. You can upload files from or
download files to the network.
The format is \\server\shared folder.
Use the gear button next to Network Share to access the settings.

Time Synchronization Used to synchronize the Neo5 system time with a Network Time
Protocol (NTP) server.

OPC UA Interface Used to set an Open Platform Communication Unified

Architecture (OPC UA) interface configurations.

14.2 Report Descriptions

Table 14-2 gives a description of each print report.

Reports can be saved to the locations that follow:
• System/Reports folder in the Neo5 hard drive
• USB device, if configured
• Shared folder on a network, if configured.

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Table 14-2 Report Descriptions

Report Type Description

Zone Information — Brief From the Text View screen, the following will be saved to a file:
• Zone Number
• Setpoint and Units
• Actual Temperature and Units

Zone Information — Detailed From the Text View screen, the following will be saved to a file:
• Zone Number
• Zone Name
• Setpoint
• Temperature
• Power
• Amperage
• Leakage
• Regulation Mode
• Alarm Limit
• Abort Limit
• Watts
• Resistance
• Full Load Watts
• Voltage

Diagnostics From the Test Results screen, print the following to file:
• Zone Number
• Zone Name
• Sensor
• Fuses
• T/C
• Amperage
• Volts AC
• Watts
• Wiring
• Isolation
• Earth Leakage
• Bake Out
• Time
• Resistance

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Table 14-2 Report Descriptions (Continued)

Report Type Description

Mold Setup • Zone Number
• Zone Name
• Setpoint
• Minimum Setpoint Limit
• Maximum Setpoint Limit
• Power Limit
• Alarm
• Abort
• AMC
• PCM
• Regulation
• Manual Standby Setpoint
• Remote Standby Setpoint
• Manual Boost Setpoint
• Remote Boost Setpoint
• Sensor Input
• Assigned Leader
• Output (Zero Cross or Phase Angle)
• Earth Leakage Enable
• Control (PID or ART)
• P (Proportional)
• I (Integral)
• D (Derivative)
• No Response

Zone Calibration • Date and Time

• Mold Folder and Mold Setup
• System Status
• Low Test Value
• High Test Value
• Zone Number:
— Low Value Before Calibration
— High Value Before Calibration
• Zone Number:
— Value After Calibration

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Table 14-2 Report Descriptions (Continued)

Report Type Description

Power Deviation Data • Date and Time
• Mold Folder and Mold Setup
• System Status
• Power Deviation Enable
• Use Calculated Limit
• Sample Period
• Stabilization Time
• Minimum Deviation Limit
• User Specified Deviation Limit
• Zone Number
• Zone Name
• Heater Type
• Zone Status
• Base Average
• Relative Tolerance
• Base Delta
• Power Average
• ± Tolerance
• Deviation
• Global Compensation
• Compensation Power
• Sample
• Error Count
• Error Active

Event Data • Date and Time

• Mold Folder and Mold Setup
• System Status
• Number of Events:
— Date/Time
— Source
— Event Type
— Mold Folder Name
— Mold Setup Name
— Event Details

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Chapter 15 Digital I/O

The Neo5 has four inputs and four outputs available as a paid option.
The four Inputs are:
• Remote Standby
• Remote Boost
• Remote Start
• Remote Stop
The four Outputs are:
• Alarm
• Abort (PCM)
• At Temperature
• Run Light
The input and output connectors are located on the back of the Neo5 (see Section 16.2). If
you need help to connect the Neo5 inputs and outputs, contact your Husky Regional Service
and Sales Office.
Select the Digital I/O button in the System Configuration group of the Neo5 Home screen.

The Digital I/O screen shows (refer to Figure 15-1).

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Figure 15-1 Digital I/O Screen

Table 15-1 describes the column headers on the Digital I/O screen.

Table 15-1 Digital I/O Screen Column Headers

Identifiers Description
Active Indicates the logical state of the I/O signal. This displays the final
state of the signal after the optional invert is applied.

Level Indicates the physical (electrical) state of the I/O at the pin. This
state equals the logical state after it is optionally inverted, by a
normally close signal.

Name The name of the input/output.

Invert When enabled, the input/output signal is true when the signal
goes high to low (versus normal low to high).

In Use Select the checkbox to enable the input/output.

Pins The connector pins used for the input/output.

After you have made the applicable connection, for each input and output being used, select
invert if necessary. Select "In Use" to enable the input/output.

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15.1 Digital I/O Connector Pin-Out Description

The sections that follow include the connection descriptions for all of the optional Inputs and
Outputs available for the Neo5.

15.1.1 Digital Inputs

Table 15-2 describes the Neo5 digital inputs.

Table 15-2 Digital Inputs

Optional Name Description

Remote Standby Places all zones that have a Remote Standby setpoint into Standby
mode (Lower setpoint) whenever this input signal is activated.

Remote Boost Places all zones that have a Remote Boost setpoint into the Boost
mode (Higher setpoint) whenever this input signal is activated.

Remote Start Places the system in start mode whenever this signal is remotely
activated. This state will remain until the STOP key is selected or
Remote Stop is activated.

Remote Stop Places the system in stop mode whenever this signal is remotely
activated. This state will remain until the START key is selected or
Remote Start is activated.
NOTE: You cannot start the system when this input is active.

15.1.2 Digital Outputs

Table 15-3 describes the Neo5 digital outputs.

Table 15-3 Digital Outputs

Optional Name Description

Alarm Activated when any Alarm or Abort condition occurs. This state will
remain until the alarm condition is CLEARED or RESET.

Abort (PCM) Activated when an Abort condition occurs and the PCM setting in
the Quick Set screen is set to System for the problem zone. This state
will remain until the alarm condition is CLEARED or RESET.

At Temperature Activated ONLY when all zones are above the Under Temperature
alarm limit. This state will remain until any zone drops below the
Under Temperature alarm limit.

Run Light Activated whenever the START button is pressed. This state will
remain until the system is placed in STOP mode.

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15.1.3 Input Connector Pin-Out

Table 15-4 shows the connection details for all the inputs wired for dry contacts (No voltage).

CAUTION!
Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage to any of
the Inputs. Doing so could damage the Neo5.

Table 15-4 Digital Input Pin-Outs (Wiring for Dry or No Voltage Contacts)

Connector/Pin Field Cable Wire Color Signal Function

Input / 1 Black
Remote Standby
Input / 2 Red

Input / 3 White
Remote Boost
Input / 4 Green

Input / 5 Orange
Remote Start
Input / 6 Blue

Input / 7 Brown
Remote Stop
Input / 8 Yellow

Input / 9 Violet Not Used

Table 15-5 shows the connection detail for all the inputs wired to accept voltage from an
external source.

CAUTION!
Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage greater
than 30 VDC to any of the inputs. Doing so could damage the Neo5.

Table 15-5 Digital Input Pin-Outs (Wiring to Accept Voltage from External Source)

Connector/Pin Field Cable Wire Color External Voltage Source Signal Function
Input / 1 Black Not Used
Remote Standby
Input / 2 Red +5-30 VDC

Input / 3 White Not Used

Remote Boost
Input / 4 Green +5-30 VDC

Input / 5 Orange Not Used

Remote Start
Input / 6 Blue +5-30 VDC

Input / 7 Brown Not Used

Remote Stop
Input / 8 Yellow +5-30 VDC

Input / 9 Violet -VDC Reference

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15.1.4 Output Connector Pin-Out

Table 15-6 shows the connection details for all of the outputs.

CAUTION!
Electrical hazard - risk of damage to the equipment. DO NOT apply a voltage greater
than 30 VDC at 2 amps to any of the Outputs. Doing so could damage the Neo5.

Table 15-6 Digital Output Pin-Outs

Connector/Pin Field Cable Wire Color Signal Function

Input / 1 Black
Alarm
Input / 2 Red

Input / 3 White
Abort (PCM)
Input / 4 Green

Input / 5 Orange
At Temperature
Input / 6 Blue

Input / 7 Brown
Run Light
Input / 8 Yellow

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Chapter 16 Maintenance

This chapter describes the maintenance tasks required to maintain the Neo5. Do the
maintenance tasks only when necessary.
Periodically, and before starting the equipment, check that all cables and cable connections
are free from wear or damage. Do not operate equipment if the cables are damaged. Replace
all the cables that appear damaged.

Procedure Reference
Replacing an Intelligent Control Card Section 16.3.1

Replacing a Blown Fuse on an Intelligent Control Card Section 16.3.2

Removing and Replacing the Touch Monitor — Integrated Configuration Section 16.4.1

Removing and Replacing the MCU — Integrated Configuration Section 16.4.2

Removing and Replacing the Touch Monitor — Freestanding Configuration Section 16.4.3

Removing and Replacing the MCU — Freestanding Configuration Section 16.4.4

Removing and Replacing the Operator Interface — Freestanding Section 16.4.5

Configuration

Cleaning the System Section 16.6

Basic Troubleshooting Section 16.7

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16.1 Servicing the System

The Neo5 systems are based on two user serviceable components:

• X-Series or H-Series Intelligent Control Cards
• Neo5 Operator Interface
Figure 16-1 shows a Neo5 integrated configuration. Figure 16-2 shows a Neo5 freestanding
configuration.

Figure 16-1 Neo5 Integrated Configuration (C6-2 Configuration shown)

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Figure 16-2 Neo5 Freestanding System Configuration (Single Stack)

Figure 16-3 and Figure 16-4 show the main power switch locations.

WARNING!
Hazardous voltages - risk of death or serious injury. Before servicing the Altanium
Neo5 lock out and tag the Main Power switch in accordance with local codes.

Figure 16-3 Neo5 Main Power Switch - Integrated Configuration (C6-1 Configuration Shown)

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Figure 16-4 Neo5 Main Power Switch - Freestanding Configuration (Single Stack)

16.2 Cable Connections

Depending on the Neo5 configuration, there will be cable connections at the back and front
of the controller.
The insulation level of control cables and devices connected to the Neo5 connectors are:
• 500 V when the devices are powered by a 380 VAC or 415 VAC system
• 300 V when the devices are powered by a system up to 240 VAC.

16.2.1 Cable Connections — Integrated Configuration

Figure 16-5 and Figure 16-6 show the connections for an integrated configuration.
Table 16-1 gives the connection descriptions.

Figure 16-5 Cable Connections - Front of Neo5

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Figure 16-6 Cable Connections - Rear of Neo5

Table 16-1 Cable Connections (Integrated Configuration)

Item Cable Connection Description

1 Horn Audible alarm.

2 LCD1 (HDMI) Video signal to touch monitor.

3 Touch Screen Touch screen signal to the touch monitor.

4 Ethernet User interface to customer networks.

5 USB USB port for importing and exporting files.

6 Input Digital inputs (Optional).

7 Output Digital outputs (Optional).

16.2.2 Cable Connections — Freestanding Configuration

Figure 16-7 shows the connections for an integrated configuration. Table 16-2 gives the
connection descriptions.

Figure 16-7 Cable Connections (Freestanding Configuration)

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Table 16-2 Cable Connections (Freestanding Configuration)

Item Cable Connection Description

1 100-240 VAC In Main AC power from the Altanium mainframe.

2 Output COMM CAN bus communication to the Altanium mainframe.

3 Touch Screen Touch screen signal to the touch monitor.

4 Ethernet User interface to customer networks.

5 USB USB port for importing and exporting files.

NOTE: Use the USB port at the front of unit for easier access.
6 LCD1 (HDMI) Video signal to touch monitor.

7 Input Digital inputs (Optional).

8 Output Digital outputs (Optional).

16.3 Intelligent Control Cards

There are two series of Intelligent Control Cards (ICC) that you can install:
• X-Series (ICC2)
• H-Series (ICC3)
The X-Series card is identifiable by the large square blue or brown transformer mounted near
the heatsink and is the older generation of Altanium cards (refer to Figure 16-8). The H-Series
card is identifiable by the yellow numbered label that indicates how many zones it supports
(refer to Figure 16-9). H-Series cards are the newest generation of Altanium cards.
Although they look similar, the X-Series and H-Series cards are not compatible with one
another and must only be used in systems of like card types.

Figure 16-8 X-Series Intelligent Control Card

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Figure 16-9 H-Series Intelligent Control Card

Both series of cards plug into backplanes that are installed into the bays of the Neo5
mainframe (refer to Figure 16-10). The cards manage the power being delivered to the
heaters, the thermocouple feedback and control and circuit protection.

Figure 16-10 Mainframe Bay with Backplane Exposed

IMPORTANT!
Although they look similar, X-Series and H-Series cards use different backplanes and
are not compatible with each other.

IMPORTANT!
You must have an Intelligent Control Card present in the position labeled 1 in all
backplanes for the system to function properly.

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16.3.1 Replacing an Intelligent Control Card

To replace an intelligent control card, do the steps that follow:

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.
The ICC2 and ICC3 cards are electrostatic discharge sensitive. Use a ground strap when
handling the cards.

1. Locate the card cage that contains the faulty ICC (refer to Figure 16-11).

Figure 16-11 Card Cage Location

CAUTION!
Mechanical failure mode - attempting to remove a card when the top and bottom
heatsink mounting fasteners are not fully disengaged from the female threads on the
cabinet can result in catastrophic damage to the card.

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2. Loosen the top and bottom slotted fasteners on the heat sink (refer to Figure 16-12).
NOTE: These two fasteners are captive so they will not fall into the system or get lost on
the floor.

Figure 16-12 Slotted Fasteners

3. Slide a screwdriver between the silver post and the ledge on the cabinet and gently pry
the card out (refer to Figure 16-13).

Figure 16-13 ICC Removal

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CAUTION!
Static electricity hazard - risk of damage to the equipment. The Intelligent Control
Cards are electrostatic discharge sensitive. Do not, under any circumstances, place any
Intelligent Control Card on carpets, rugs, or other material that is likely to create a
static charge.

4. Carefully put the card on an earthed/grounded surface.

5. Slide the new card into to the slot and push the card slowly and firmly back into place.
NOTE: An incorrectly oriented card will not seat correctly.
6. Tighten the top and bottom slotted fasteners on the heat sink.

16.3.2 Replacing a Blown Fuse on an Intelligent Control Card

To replace a fuse on an ICC, do the steps that follow:

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.
The ICC2 and ICC3 cards are electrostatic discharge sensitive. Use a ground strap when
handling the cards.

1. Locate the card cage that contains the ICC that has a blown fuse (refer to Figure 16-11).
2. Loosen the top and bottom slotted fasteners on the heat sink (refer to Figure 16-12).
NOTE: These two fasteners are captive so they will not fall into the system or get lost on
the floor.
3. Slide a screwdriver between the silver post and the ledge on the cabinet and gently pry
the card out (refer to Figure 16-13).

CAUTION!
Static electricity hazard - risk of damage to the equipment. A static charge could
damage the Intelligent Control Card. Do not place the Intelligent Control Card on
carpets, rugs, or other material that is likely to create a static charge.

4. Carefully put the card on an earthed/grounded surface.

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5. Remove the faulty fuse (refer to Figure 16-14 for fuse location examples).
NOTE: 20- and 30-Amp cards will only have two fuses. 5-Amp cards will have 8 fuses.

Figure 16-14 ICC Fuse Locations

6. Install a fuse with one that is of identical type and rating as the fuse that was removed.
NOTE: Husky recommends SIBA 712540 Series or equivalent fuses.
7. Make sure the fuse is fully seated.
NOTE: Poor seating will cause a hot spot, which can cause problems for the system
8. Slide the new card into to the slot and push the card slowly and firmly back into place.
NOTE: An incorrectly oriented card will not seat correctly.
9. Tighten the top and bottom slotted fasteners on the heat sink.

16.4 Neo5 Operator Interface

The Neo5 operator interface is used to enter and display molding parameters. It consists of
two main components: the touch monitor and the Master Control Unit (MCU). It is also
available in two different configurations: integrated and standalone.
The operator interface does not contain user-serviceable parts and should only be serviced
by replacing the touch monitor or master control unit as complete subassemblies.
Figure 16-15 shows the touch monitor and MCU for an integrated configuration.

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Figure 16-15 Neo5 Integrated Operator Interface

Figure 16-16 shows the touch monitor and MCU for a freestanding configuration.

Figure 16-16 Neo5 Freestanding Operator Interface

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16.4.1 Replacing the Touch Monitor — Integrated Configuration

To replace the touch monitor on an integrated configuration system, do the steps that
follow:

WARNING!
Electrical and mechanical hazard - risk of damage to the equipment. Turn off all power
to the system and disconnect it completely from the main input power. Follow the local
Lock Out Tag Out procedures.

WARNING!
Pinch Point Hazard - keep hands and fingers clear of the Neo5 touch monitor hinge
mechanism.

1. Rotate the touch monitor to the full forward position, as shown in Figure 16-17.

Figure 16-17 Rotate Monitor

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This will expose the mini-USB connector, HDMI connector and top set of fasteners
holding the touch monitor to the mounting bracket (refer to Figure 16-18).

Figure 16-18 Mini-USB and HDMI Connectors

2. Disconnect the mini-USB and HDMI connectors at the back of the touch monitor, as
shown in Figure 16-19.

Figure 16-19 Disconnect the Mini-USB and HDMI Connectors

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3. Loosen the two top fasteners using a 4mm socket wrench or nut driver (refer to
Figure 16-20).

IMPORTANT!
Only loosen the fasteners. The mounting holes in the bracket holding the touch
monitor are slotted key holes that allow the monitor to be removed without removing
the fasteners completely!

Figure 16-20 Loosen the Top Fasteners

4. Rotate the touch monitor to the full back position and loosen the two bottom fasteners
(refer to Figure 16-21).

Figure 16-21 Loosen the Bottom Fasteners

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5. Securely grip the touch monitor and slide it upwards until the fasteners have cleared the
top mounting slots and bottom key holes. Pull forward to remove the touch monitor
from the mounting bracket. Refer to Figure 16-22.

Figure 16-22 Slide Monitor Off of Fasteners

6. Remove the two top and bottom fasteners from the touch monitor and install them on
the threaded studs on the back of the new touch monitor (refer to Figure 16-23).

Figure 16-23 Slide Monitor Off of Fasteners

7. Do step 1 through step 6 in reverse order to install the new touch monitor.

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16.4.2 Replacing the MCU — Integrated Configuration

To replace the MCU on an integrated configuration system, do the steps that follow:

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.

WARNING!
Pinch Point Hazard - keep hands and fingers clear of the Neo5 touch monitor hinge
mechanism.

1. Rotate the touch monitor to the full back position to expose the touch screen and LCD1
connectors (refer to Figure 16-24).

Figure 16-24 Touch Screen and LCD1 Connector Locations

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2. Unplug the touch screen and LCD1 connectors at the front of the MCU (refer to
Figure 16-25).

Figure 16-25 Remove Touch Screen and LCD1 Connectors

3. Locate and remove two mounting fasteners holding the MCU in place at the back of the
unit (refer to Figure 16-26).

Figure 16-26 MCU Mounting Fasteners

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4. Put your hand on the front of the MCU and push it backwards to disengage the hidden
hooks that hold it in place on top of the mainframe (refer to Figure 16-27).

Figure 16-27 Disengage Hooks

IMPORTANT!
Do not pull up on the MCU because it is held into position by hooks that fit into slots in the
top of the mainframe and are hidden from sight! Push back on the MCU from the front to
disengage the hooks and then lift up.

5. Once the hooks have disengaged carefully rotate the MCU upwards towards the front of
the unit to expose the power and communication cables (refer to Figure 16-28).

Figure 16-28 Power and Communication Cables

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6. Carefully remove the power and communication connectors from the pocket at the
bottom of the MCU and continue to rotate the unit upwards until it is resting on its front
face (refer to Figure 16-29).

Figure 16-29 Rotate the MCU Upwards

7. Using your fingers, gently rotate the power and communication couplings to
disconnect the cables from the top of the mainframe (refer to Figure 16-30).

Figure 16-30 Disconnect Power and Communication Connectors

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8. After the power and communication cables are disconnected, carefully lift the MCU
from the mainframe (refer to Figure 16-31).

Figure 16-31 Remove the MCU from the Mainframe

9. Do step 1 through step 8 in reverse order to install the new MCU.

16.4.3 Replacing the Touch Monitor — Freestanding Configuration

To replace the touch monitor on a freestanding configuration system, do the steps that
follow:

WARNING!
Electrical and mechanical hazard - risk of damage to the equipment. Turn off all power
to the system and disconnect it completely from the main input power. Follow the local
Lock Out Tag Out procedures.

WARNING!
Pinch Point Hazard - keep hands and fingers clear of the Neo5 touch monitor hinge
mechanism.

1. Rotate the touch monitor to the full forward position to expose the mini-USB connector,
HDMI connector and top set of fasteners that hold the touch monitor to the mounting
bracket (refer to Figure 16-32).

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Figure 16-32 Rotate the Monitor on a Freestanding Configurated System

2. Unplug the mini-USB and HDMI connectors at the back of the touch monitor and loosen
the two top fasteners using a 4mm socket wrench or nut driver (refer to Figure 16-33).

IMPORTANT!
Only loosen the top fasteners. The top mounting holes in the bracket holding the touch
monitor are slotted and allow the monitor to be removed without removing the top
fasteners completely!

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Figure 16-33 Loosen the Top Fasteners

3. Rotate the touch monitor to the full back position and completely remove the two
bottom fasteners (refer to Figure 16-34).
NOTE: These mounting holes are not slotted, so the nut has to be removed completely
to allow the touch monitor to be removed.

Figure 16-34 Remove the Bottom Fasteners

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4. Securely grip the touch monitor and slide it upwards until the fasteners have cleared the
top mounting slots and pull forward to remove the touch monitor from the mounting
bracket (refer to Figure 16-35).

Figure 16-35 Remove Monitor

5. Ensure the fasteners are pre-installed on the top threaded studs and the fasteners are
left off the bottom studs on the back of the touch monitor (refer to Figure 16-36).

Figure 16-36 Fastener Check

6. Do step 1 through step 5 in reverse order to install the new touch monitor.

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16.4.4 Replacing the MCU — Freestanding Configuration

To replace the MCU on a freestanding configuration system, do the steps that follow:

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.

1. Locate the Touch Screen and LCD1 connectors at the bottom of the MCU enclosure
(refer to Figure 16-37).

Figure 16-37 Touch Screen and LCD1 Connector Locations

2. Disconnect the touch screen and LCD1 connectors at the bottom of the MCU and then
disconnect the power and communication connectors (refer to Figure 16-38).

Figure 16-38 Disconnect the Connectors

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3. Locate the four fasteners holding the MCU to the mounting bracket (refer to
Figure 16-39).
NOTE: The bracket is located between the Touch Monitor and the MCU enclosure.

Figure 16-39 Fastener Locations

4. Loosen the two top fasteners holding the MCU to the mounting bracket using a 4mm
Allen key or hex wrench (refer to Figure 16-40).

IMPORTANT!
Only loosen the top fasteners. The top mounting holes in the bracket holding the MCU
are slotted and allow the unit to be removed without removing the top fasteners
completely!

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Figure 16-40 Loosen the MCU Top Fasteners

5. Locate and completely remove the two bottom fasteners (refer to Figure 16-41).
NOTE: These mounting holes are not slotted, so the screws must be removed
completely to allow the MCU to be removed.

Figure 16-41 Remove the Bottom MCU Fasteners

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6. Securely grip the MCU and slide it upwards until the fasteners have cleared the top
mounting slots and pull forward to remove the MCU from the mounting bracket.
7. Do step 1 through step 6 in reverse order to install the new MCU.
NOTE: Before you start the new MCU install, make sure that the fasteners are pre-
installed on the top threaded holes and the fasteners are not installed on the
bottom holes on the back of the MCU (refer to Figure 16-42).

Figure 16-42 MCU Pre-Install Fastener Setup

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16.4.5 Replacing the Operator Interface — Freestanding Configuration

To replace the operator interface for a Neo5 freestanding configuration system, so the steps
that follow:

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.

1. Locate the four fasteners holding the operator interface to the top of the mainframe and
the power and communication connectors (refer to Figure 16-43).

Figure 16-43 Operator Interface Fastener and Cable Locations

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2. Disconnect the power and communication connectors, as shown in Figure 16-44.

Figure 16-44 Disconnect Operator Interface Power and Communication Connectors

3. Remove the two fasteners holding the operator interface at the front of mainframe
(refer to Figure 16-45).

Figure 16-45 Remover the Front Fasteners

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4. Remove the two fasteners holding the operator interface at the back of mainframe (refer
to Figure 16-46).
NOTE: This step requires a screwdriver short enough to clear the MCU located above the
fasteners.

Figure 16-46 Remover the Rear Fasteners

5. Securely grip the operator interface from the silver mounting pole and carefully lift the
unit from the top of the mainframe.
6. Put the operator interface on a stable surface (refer to Figure 16-47).

Figure 16-47 Put the Operator Interface on a Stable Surface

7. Do step 1 through step 5 in reverse order to install the new operator interface.

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16.5 Neo5 Mobile Stand

The Neo5 integrated configuration is available with a mobile stand as a paid option. The
mobile stand allows the touch monitor of the Neo5 integrated configuration to be raised to
an optimal viewing height (1320 mm – 52 in.) and easier to move from place to place. There
are two variants of the mobile stand (refer to Figure 16-48):
• C6-1 Mobile Stand (Tall stand assembly)
• C6-2 Mobile Stand (Short stand assembly)

Figure 16-48 Neo5 Mobile Stand Configurations

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16.5.1 Installing Neo5 on the Mobile Stand

The Neo5 mobile stand and controller come as separate pieces and must be assembled.
To install the Neo5 on the mobile stand, do the steps that follow:

WARNING!
Electrical and mechanical hazard - risk of serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power. Follow the local Lock Out Tag Out procedures.

1. Carefully place the Neo5 controller on its side to locate and remove the 4x leveling pads
(refer to Figure 16-49).
NOTE: These pads are hand tight and do not require any tools for removal.

Figure 16-49 Remove Leveling Pads

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2. Place the mobile stand in an open flat area of the floor and set the brakes, located on the
front wheels (refer to Figure 16-50).

IMPORTANT!
Ensure that the correct stand and controller combination is used. This will prevent the
assembly from becoming top heavy and tipping over. The C6-1 configuration fits to the
taller mobile stand and the C6-2 fits to the shorter mobile stand.

Figure 16-50 Mobile Stand Brakes and Mounting Holes

3. Locate the 4x mounting holes on the top plate of the mobile stand (refer to
Figure 16-50).

WARNING!
Heavy object - two person lift requirement. To avoid injury ask for assistance and use
proper lifting technique when lifting the Neo5. Refer to Section 1.8.1.

4. With two people and a proper lifting technique, refer to Section 1.8.1, put the Neo5 on
the mobile stand top plate.

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5. Put the Neo5 in the center of the top plate (Figure 16-51), so that the mounting holes in
the top plate align with the threaded holes at the bottom of the Neo5.

Figure 16-51 Mobile Stand Brakes and Mounting Holes

6. With the Neo5 controller in the center of the mobile stand, put the four leveling pads
through the holes and firmly tighten by hand (refer to Figure 16-52).

Figure 16-52 Install the Leveling Pads

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7. Use the tray at the bottom of the stand to store cables related to the controller (refer to
Figure 16-53).

Figure 16-53 Mobile Stand Bottom Tray

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16.6 Cleaning the System

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power.
Hazardous voltages - risk of death or serious injury. Before servicing the Altanium unit
lock-out and tag the Altanium Main Power switch in accordance with local codes.
Use a ground strap when handling the components.

16.6.1 Mainframe (Cabinet)

• Use a damp sponge or cloth. No abrasives should ever be used on the surface. The labels
should also be wiped and no cleaners or solvents should be used.
• If a cleaner of any type must be used, a non-ammonia, non-alcohol based glass cleaner
sprayed onto a cloth, not directly onto the cabinet, is recommended.

16.6.2 Touch Monitor

To clean the touch monitor, do the steps that follow:
1. Make sure the monitor is turned off.
2. Wipe the screen with a clean, soft, lint-free cloth. This removes dust and other particles.
3. If necessary, apply a small amount of non-ammonia, non-alcohol based glass cleaner
onto a clean, soft, lint-free cloth, and wipe the screen.

CAUTION!
Mechanical hazard - risk of equipment damage. Do not spray or pour any liquid
directly onto the screen or case. Spray cleaner onto a lint-free cloth. If the liquid
droplets dry on the monitor, the liquid may permanently stain or discolor the monitor.

CAUTION!
Mechanical hazard - risk of equipment damage. The display area is highly prone to
scratching. Do not use ketone type material (for example, acetone), ethyl alcohol,
toluene, ethyl acid or methyl chloride to clean the panel. These products may
permanently damage the panel and void the warranty.

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16.7 Basic Troubleshooting

Table 16-3 give the possible solutions for issues that could occur.

WARNING!
Electrical and mechanical hazard - risk of death, serious injury and/or damage to the
equipment. Turn off all power to the system and disconnect it completely from the
main input power.
Hazardous voltages - risk of death or serious injury. Before servicing the Altanium unit
lock-out and tag the Altanium Main Power switch in accordance with local codes.
Use a ground strap when handling the components.

Table 16-3 Troubleshooting Procedures

Problem Potential Cause Solution
Read Time Out The card cannot communicate (bad, If the fault is on a zone, remove and
not installed or not powered). re-seat the card or replace the card.
The card is not at the address If the fault is on many zones, check
expected. the supply to the controller to make
The CAN bus (cables & backplanes) sure there is not a missing phase.
cannot convey data. If the fault is on all zones, check the
The operator interface cannot power and communication cable to
communicate with the CAN bus. the operator interface to make sure
they are connected correctly or
change the operator interface
computer.

Fuse Blown Short circuit in mold or cabling. Consult the mold electrical prints
Output incompatible with the and use an ohmmeter or insulation
heater. resistance meter to inspect the
Excessive voltage applied to cables and mold.
controller. This is unlikely to be a controller
issue but the connectors on the
back of the controller should be
inspected as well.

Over/Under This may be setup, sensor, output or Confirm that the Alarm window is
Temperature control related. set to an appropriate range and not
too small. Recommended: +/-10°F
(6°C).
Re-ART (Tune) the zone under
typical molding conditions
ensuring that the mold is in the
injection machine with mold
cooling on and resin in the mold.

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Table 16-3 Troubleshooting Procedures (Continued)

Problem Potential Cause Solution

Ground Fault Bad heater. Consult the mold electrical prints
Short in wiring. and use an ohmmeter or insulation
Bad Card. resistance meter to inspect the
Mis-wired mold, cable or controller. cables and mold.
Moisture in the heater. This is unlikely to be a controller
issue but the connectors on the
back of the controller should be
inspected as well.
Swap the card with a known good
unit and confirm if the error returns.
If not, replace the card.
If moisture is suspected, place the
zone setpoint at a 200°F (93°C) and
apply heat until the moisture has
been baked out of the heater.

No Response Heater is not heating sufficiently Insufficient heat can be low supply
(Undersized or low input voltage). voltage. Check the supply voltage
Temperature of the heater cannot and confirm that this mold has run
be sensed (Pinched or displaced successfully at the present voltage.
thermocouple). If not, connect the controller to a
supply with sufficient voltage.
In some cases, the current reading
may be used to determine if current
is flowing through the heater. If no
current is flowing, a wiring fault or
bad heater is likely.
Shorted, detached, mis-positioned
or pinched thermocouples are
possibilities. Check the cables and
wiring in the mold to ensure
thermocouples are properly routed
and terminated.

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Table 16-3 Troubleshooting Procedures (Continued)

Problem Potential Cause Solution

Reverse T/C Thermocouple has been connected Insufficient heat can be low supply
with reversed polarity. voltage. Check the supply voltage
Card is not calibrated. and confirm that this mold has run
Card is nonfunctional. successfully at the present voltage.
Mold is much colder than ambient. If not, connect the controller to a
supply with sufficient voltage.
In some cases the current reading
may be used to determine if current
is flowing through the heater. If no
current is flowing, a wiring fault or
bad heater is likely.
Shorted, detached, mis-positioned
or pinched thermocouples are
possibilities. Check the cables and
wiring in the mold to ensure
thermocouples are properly routed
and terminated.

No Connection, T/C Thermocouple circuit is broken. Shorting the thermocouple input

Bad thermocouple. should display an ambient
Card is not seated. temperature on the operator
Card is not calibrated. interface. If it does, the problem is
Card is nonfunctional. most likely a wiring issue. Inspect
Zone far beyond 1100 °F or 600 °C. the cables and mold for a bad
connection or broken
thermocouple.
If shorting the thermocouple input
does not display an ambient
temperature, the problem is most
likely a loss of calibration or a
nonfunctional card. Try
recalibrating the zone and if this
does not work, replace the card.

Temperature is No communication with the card. Refer to Read Time Out Error
showing 32°F or 0°C solution.

No Screen Bad touch monitor or computer. Check the supply to the controller
Missing phase. to ensure there is not a missing
phase.
Replace the touch monitor with a
known good unit to confirm if the
image is restored. If so, replace the
touch monitor.
Replace the computer with a known
good unit to confirm if the image is
restored. If so, replace the
computer.

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Appendix A Glossary of Terms

Table A-1 gives the definitions for terms and symbols used in this user guide.

Table A-1 Glossary of Terms and Symbols

AMC Automatic Manual Control

Amp or Amps Ampere or Amperes

ANSI American National Standards Institute

ART Active Reasoning Technology

°C Celsius temperature scale

CSV Comma Separated Values (file)

dBG Zone gain in decibels

DELTA 3PH The Delta configuration has the three phases connected in a triangle shape. They
(Input Power) do not normally have a neutral cable.

DIN Deutsches Institut für Normung (German Institute for Standardization)

°F Fahrenheit temperature scale
ft Foot or Feet
HMI Human Machine Interface

Hz Hertz
I/O Input/Output
ICC Intelligent Control Card
in Inch or Inches
Imperial Imperial Units or British Imperial Units (measurement)

IMM Injection Molding Machine

Integrated TX WYE 3PH Transformer Secondary supply power is used.

(Input Power)

kg Kilograms
lb Pound(s)
LCD Liquid-Crystal Display

LOTO Lockout Tagout

m Meter(s)

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 v 2.0 — January 2023 Altanium Neo5

Table A-1 Glossary of Terms and Symbols (Continued)

MCU Master Control Unit

mm Millimeter(s)

NTP Network Time Protocol

 Ohm or ohms

OPC UA Open Platform Communication Unified Architecture

PCM Priority Control Mode

PID Proportional, Integral, and Derivative

RH Relative Humidity

Single Phase A two-wire (supply and neutral) power input is used.

(Input Power)

T/C Thermocouple

VAC Volts Alternating Current

VDC Volts Direct Current

Wye 3PH+N A Wye three phase supply plus neutral configuration is when all the loads in an AC
(Input Power) system are connected at one point. The configuration has looks like a Y shape.

Page 238
Index

A ART 2.0 136

Abort conditions 161 ART settings, Quick Set screen 129
Accept/cancel buttons 20 Assign advanced or basic mode to user
Active Reasoning Technology 134 profile 77
ART 2.0 136 Automatic thermocouple wiring 146
settings, quick set 129
Add user 40 B
Administration and security 37 Bake out cycles, configuring 152
Advanced settings, Quick Set Bake out, wet heater 152
screen 126 Basic setup screen 65
Advanced setup screen 54 Basic/advanced mode 21
Advanced/basic mode 21 Buttons
Alarm accept/cancel 20
abort conditions 161 alarm 25
buttons 25 controller function 23
conditions 160 data collection and monitoring 27
screen 155–157 file management 89
Alarm window 131 group controller function 100
Alarms multi-group view screen 99
clearing 157 navigation 24
opening screen 156 save dialog window 36
AltaStart 153 save now 34

Page 239
 system and user management 25 Default screen settings 78
system configuration 29 default parameters 80
temperature management 27 overview 79
zone views 26 Define group layout order 100
Delete user 44
C Determine heater size 10
Cable connections 200 Diagnostics, mold 139
freestanding configuration 201 Digital I/O 191
integrated configuration 200 pin-out descriptions 193
Calibration, zone 132 digital inputs 193
Cleaning digital outputs 193
mainframe 233 input connector 194
touch monitor 233 output connector 195
Collapse/expand zones shown in Dimensions and weights 5
group 103 Display/hide zones 114
Color codes
thermocouple types 12 E
Compare mold test results 146 Earth leakage 152
Configuring zones 10 Enable
phase angle control 10 security 49
zero cross control 10 staged startup 171
Connections Environmental operating
controller to mold 13 specifications 4
power source 13 Equipment
Control settings, Quick Set screen 127 lifting 6
Controller Area Network (CAN) 182 purpose 3
Customize 53 ratings 4
advanced setup 54 restrictions of use 3
default screen settings 78 safety signs 2
import/export default settings 83 Errors
import/export screen settings 75 shutdown 161
screen buttons 54 warning 160
system setup screen 75 Event History screen 157–159
filtering events 159
D
Expand/collapse zones shown in
Data group 103
collection and monitoring
buttons 27 F
exchange 185 Fast heating 154
report descriptions 187 File management buttons 89
reports, process data, and File Management screen 87
settings 185 Files screen 87
recording 175–183 Filtering history events 159

Page 240
Frequently used fields settings, Quick Interface, operator 19
Set screen 111 Introduction 1
Function buttons 23
Fuse, replacing ICC 206 K
Keyboards, screen 31
G Keypads, screen 31
General safety 1 use 32
Glossary of terms 237
Graphic plot point, view 177 L
Graphic process traces 176 Layout order, define group 100
Groups Leakage, earth 152
add zones to 96 Lifting instructions, controller 6
change header color 102 Limit, earth leakage 152
collapse/expand zones shown 103 Log in/log out 37
controller function buttons 100
create 94 M
define layout order 100 Maintenance 197–236
delete 97 cable connections 200
remove zone 97 intelligent control cards 202
MCU replacement
H freestanding configuration 221
Header and footer, screen 22 integrated configuration 213
Header color, change group 102 monitor replacement
Heat circuit test 151 freestanding configuration 217
Heater integrated configuration 209
determine size 10 Neo5 operator interface 207
Ohm’s Law, use of 11 operator interface replacement 225
types 124 system, servicing 198
Heating troubleshooting 234
fast 154 Manage users 39
mold 151 Manual boost, Quick Set screen 118
Hide/display zones 114 Manual standby, Quick Set screen 116
Home screen, Neo5 20 MCU replacement
freestanding configuration 221
I
integrated configuration 213
Import/export Menus, selection 31
customize screen settings 75 Mobile stand
default settings 83 description 228
Indicators, system status 23 Neo5 installation 229
Input wiring 3 Modes
Intelligent Control Cards (ICC) basic/advanced 21
fuse replacement 206 system 30
maintenance 202
replacing 204

Page 241
 Mold Operator interface
heat circuit test 151 description 19
heating 151 maintenance 207
alarms 155 monitor, replace
earth leakage 152 integrated 209
event history 157 Operator interface, replacement 225
soft start routine 154 Override, security assignments 49
setups 87
P
startup 151
tuning, ART 2.0 136 Password, change user 45
Mold diagnostics 139–149 Plot point, view 177
test 141 Power
definitions 143 deviation 177
configure 179
maximum test time 142
troubleshooting 181
zone cooling time 142
staging, set 174
test results 143
Process adjustments 93
comparison 146
Multi-Group View screen 97–103
test settings 139 Neo View screen 104–106
Mold setup file Quick Set screen 110
copy 91 Text View screen 107–109
delete 91 Zone Calibration screen 132–134
load existing 90 zone groups 94
save changes 90 zone selection 93
save current file as new 90 Process monitoring 175–177
transfer data 91 change zones 176
Monitor graphic process traces 176
cleaning 233 view plot point 177
replacement Purpose, equipment 3
freestanding configuration 217
integrated configuration 209 Q
Monitoring and data collection Quick adjustment panel 109
buttons 27 Quick Set screen 94, 110–136
Multi-Group View screen 97–103 advanced settings 126
ART settings 129
N control settings 127
Navigation buttons 24 frequently used fields 111
Neo View screen 104–106 heater types 124
manual boost 118
O
manual standby 116
Ohm’s Law 11 remote boost 122
Open loop control 9 remote standby 119
setpoint limits 115
zone edit settings 112
zone follower 130

Page 242
R Security
Ratings, equipment 4 assignments override 49
Recording, data 175–183 enable 49
Remote boost, Quick Set screen 122 screens 39
Remote standby, Quick Set screen 119 settings list 49
Report descriptions 187 settings screen 46
Restrictions of equipment use 3 Security and administration 37
Selection menus, screen 31
S Servicing the system 198
Safety Setpoint limits, Quick Set screen 115
general 1 Setpoints, enter value with keypad 32
signs 2 Shutdown errors 161
Save dialog window button 36 Signs, equipment safety 2
Save now button 34 Snubberless TRIAC 10
Screen keyboards 31 Soak timers, setting 173
Screens Soft start routine 154
advanced setup, customize 54 Sorting, Text View screen 109
Alarm 155–157 Staging
clearing 157 enable and disable 171
opening 156 soak timers, set 173
basic setup 65 startup and shutdown 171
basic setup, customize 65 temperature and power, set 174
CAN Info 182 Stand, mobile system 228
Customize 53 Startup
Data Exchange 185–190 before you start controller 13
Digital I/O 191–195 Neo5 system 151
Event History 157–159 power source connection 13
File Management 87 procedure checklist 14
header and footer 22 Status indicators 23
Multi-Group View 97–103 Supply Voltage screen 15
Neo View 104–106 System
Neo5 home screen 20 cleaning (mainframe and touch
Power Deviation 177–181 monitor) 233
Process Monitor 175–177 configuration buttons 29
Quick Set 94, 110–136 modes 30
Security 46 servicing 198
Staging 171–174 setup 163–170
Supply Voltage 15 startup 151
System Setup 163–169 System and user management
system setup, customize 75 buttons 25
Text View 107–109 System setup screen 75
User Management 39
Zone Calibration 132–134

Page 243
 T W
Temperature Warning errors 160
control, hot runner 9 Weights and dimensions 5
management buttons 27 Wet heater bake out 152
open loop control 9 Wiring, input 3
staging, set 174
types of control 9 Z
Terms, glossary of 237 Zone edit settings, Quick Set
Test screen 112
automatic thermocouple wiring 146 display/hide zones 114
heat circuit 151 lock/unlock zones 114
results comparison, mold 146 zone name 113
results, mold 143 Zone follower, Quick Set screen 130
Text View screen 107–109 Zone views buttons 26
sorting by column 109 Zones
zone selection 109 add zones to groups 96
Thermocouple types and color calibration 132
codes 12 change in Process Monitor
Touch monitor replacement screen 176
freestanding configuration 217 change number in system 169
integrated configuration 209 configuring 10
Traces, graphic process 176 create groups 94
TRIAC, snubberless 10 delete group 97
Troubleshooting display/hide 114
maintenance 234 followers, set 130
power deviation 181 groups 94
Tuning, ART 2.0 136 lock/unlock 114
Types of temperature control 9 name, enter 113
remove zone from group 97
U selection 93
UniStart 153 selection on Text View screen 109
User management and system
buttons 25
User management screen 39
Users
add 40
assign advanced or basic mode to
profile 77
change user password 45
delete 44
manage 39

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