GÜNTHER

Hot Runner Systems

Control Unit

DPT2 / DPT4
User Manual

Production Index A, 10. 97

Gu n t h e r H o t R u n n e r S ys t e m s User Manual Con trol Unit DPT2/DPT4

GÜNTHER Hot Runner Control Unit DPT2 and DPT4

1. Safety Information
The DPT2/DPT4 is built and tested according to safety standards declared by the European
Council of Assimilation of Legal Regulations (cf. Appendix B) and has left the factory in
perfect condition. In order to maintain this condition and for safe operation, please read this
User Manual carefully and follow the instructions.
Ensure that your local supply voltage corresponds to the unit´s nominal voltage before you
switch on. For safe operation, the unit must be plugged into an earthed socket. Any
disconnection of the earthed conductor, e.g. by using an extension flex without earthed
conductor, may cause severe danger!

Caution: Always disconnect the unit before opening! Pull mains plug!
This control unit contains hazardous voltage. Any repair and service work must be carried out
by qualified and authorized personnel only. The components inside the unit are maintenance-
free for our customers. They are exclusively serviced by Gunther Hot Runner Systems.

For operation of the control unit, a protected socket must be used. The DPT4 is equipped with
a 16A-CEE-mains plug; the DPT2 with a 16A-shock-proof-plug. Please ensure that the
sockets used are protected sufficiently.

Note:
Refer to the chapter on installation and start-up for further instructions on the connection of
the potential-free fault output. Always unplug the unit before touching the components inside!
(Pull mains plug!)

2. Operation
The 4-zone control unit DPT4 is designed for temperture regulation of four hot runner
nozzles. It may be applied for the control of any 230V-load circuit of hot runner systems. The
unit´s output of up to 2000W allows the operation of different 230V-loads by means of the
″Pulsgruppensteuerung″ (Switching Power Control).

Please note that this unit is not designed for temperature control of low voltage nozzles (5V or
24V).

The DPT4 shown in fig. 2.1 is equipped with two 2-zone regulators type RET2 (*1). Each one
controls the temperature of two zones. They are connected to the unit´s front and can be
switched on and off separately with the red key ”1/0”.

Please note that each regulator RET2 can be switched on and off separately by pressing the
red key ”1/0”. At starting the unit, you must therefore switch on the two RET2 units in
addition to starting the unit by pressing the illuminated master key.

*1 – formerly referred to as DP2/2-230

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Fig. 2.1 Front View DPT4

Right above the illuminated master key, the four load fuses for the four control circuits are
integrated. Each heating circuit is controlled via solid-state-relays in ″Pulsgruppenbetrieb″
(Switching Power Control mode) and is fused separately. Each number of a load fuse reflects
the number of the corresponding heating zone (e.g. F1 for zone 1)

Caution !
The load fuses F1 - F4 may not exceed a maximum current of 10A!

Each microprocessor controller RET2 controls two of the max. four heating zones.
Temperature of the zones 1 and 2 is regulated by the RET2 on the left side; zones 3 and 4 by
the RET2 on the right side.

The 2-zone controller unit DPT2 is a smaller version of the 4-zone control unit DPT4. It is
basically constructed like the DPT4, yet it operates only one RET2.

Fig. 2.2 Front View DPT2

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Unlike the DPT4, the DPT2 is equipped with a shock-proof-plug, and may therefore be
plugged into any usual socket (230V). Please note that the nominal maximum current of both
the DPT2 and DPT4 is 16A.

The RET2 is easy-to-use: all possible functions of the RET2 can be performed via only three
keys. Refer to the quick reference (Appendix B) for basic instructions on the operation of the
RET2.

Please read the enclosed User Manual of the RET2 for a detailed description of the operation
and the possible adjustments of this controller unit.

3. Connection of Control Circuits

Fig. 3.1 Rear View DPT2 / DPT4 (Connection Plugs)

On the rear of control unit a load connection plug is positioned. On this modular plug, up to 4
load connection modules can be assembled, depending on the version (DPT4 or DPT2). The
DPT4 has two modules (position A and B); the DPT2 only one module (position A). Each
230V-load circuit will be connected using these solid 20A-contacts. Refer to fig. 3.2 for
information about the assignment of the connection points to the corresponding modules.
Connection point ”A3”, for example, refers to socket contact ”3” of module ”A”.

Zone 1 2 3 4
Load 1 (phase) A1 A3 B1 B3
Load 2 (zero) A2 A4 B2 B4

Fig. 3.2 Load Connection of Control Unit DPT2 / DPT4

The thermocouple of each control circuit are clamped to the 20-pin socket module at position
”E”. Please ensure that no crosswiring can occur. Depending on the version (DPT4 or DPT2),
the unit may handle up to four thermocouples.

Zone 1 2 3 4
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Thermo + 1 3 5 7
Thermo - 2 4 6 8

Fig. 3.3 Thermocouple Connection DPT2 / DPT4

3.1 ″Ready for Injection″″-Signal

The hot runner is ready for injection as soon as all control circuits are heated up to the
required operating temperature. The RET2 display indicates ”OK” for each control circuit and
the potential-free relay contact is closed. For analysis of the moulding operation you may
connect the potential-free relay contact to the control system of your machine.

Note: Only use extra-low voltage (max. 125V/1A) according to VDE standards (Germany) on
the rear side OK-plug. The necessary equipment is available at Gunther Hot Runner Systems.

3.2 Temperature Lowering

During any long-term production halt it is advisable to lower the temperature of the zones. It
is not necessary to adjust the temperature for each regulation zone – you can control the
temperature of all zones simultaneously by means of a lowering input. If you close the two
contacts of the lowering input with a switch or a potential-free contact, the set temperatures of
all zones is lowered by a preset value.

For further information on the adjustment of the temperature, please read the RET2 User
Manual.

3.3 Serial Interface

The standard configuration of the DPT4 includes an interface type RS232. This 9-pin plug is
positioned on the rear of the unit and allows direct connection of the DPT4 to a personal
computer. The Windows-Software ”DPCONTROL” makes the configuration and
visualization of all system parameters possible. It will be provided by Gunther Hot Runner
Systems as necessary.

The RET2 can be equipped with a potential-free interface module for standard types RS232,
RS485 or TTY-20mA. However, for industrial applications, e.g. communication with
machines type Arburg, Engel, etc., we recommend the use of an electrically isolated interface
module.

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4. Installation and Start-up

a) Installation
• Please position the unit where not heat accumulation will occur.
• Ensure that the sockets are sufficiently protected for connecting
 16A-CEE mains plug (DPT4)
 16A-shock-proof-plug (DPT2).
• The load fuse may not exceed 10A.

b) Start-up
• To connect the heating circuit and thermocouples, plug in load connectors.
• Plug in mains plug for power supply.
• Press master key.
• Switch on each RET2 by pressing the red key(s) ”1/0”.
• Set the desired set temperatures of all zones.
• During initial start-up you should activate each control point separately so that possible
faulty connection of either load or thermoelectric couple may be detected.
• After switching on the control unit, please wait for a few minutes until all tools are
heated up evenly.

5. Table of Faults and Defects

During the course of the operation, the RET2 is continually checking the control circuit for
faults and defects. Any fault/defect detected is indicated on the display.

Fault/Defect Possible Cause Countermeasure

A Fault report Thermocouple of Thermocouple is not Check connection
”no sensor 1” zone 1 or 3 defect connected or plug and -cable of
interrupted thermoelectric couple
B Fault report Thermocouple of Thermocouple is not Check connection
”no sensor 2” zone 2 or 4 defect connected or plug and –cable of
interrupted thermoelectric couple
C Fault report Polarity error at Polarity error at the Correct the polarity
”Pol. TH 1” thermocouple of thermo couple
zone 1 or 3
D Fault report Polarity error at Polarity error at the Correct the polarity
”Pol. TH 2” thermocouple of thermo couple
zone 1 or 3
E Fault report Load circuit of Fuse blown Exchange fuse
”no load 1” zone 1 or 3
interrupted Load not connected Check connecting
cable

F Fault report Load circuit of Fuse blown Exchange fuse

”no load 2” zone 2 or 4
interrupted Load not connected Check connecting
cable

G Significant fluctua- Thermocouple defect Check earthing of

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tion of temperature or load circuit not load circuit

(+/- 100 °C ) earthed
H Temperature in- Load circuit Check assignment of
crease not satis- (swapped) heater circuit to
factory thermoelectric couple

Caution:
With 230V-runners the heater circuits must be earthed sufficiently. Lack of earthing or
insufficiently earthed tool/heating element may cause severe errors in the temperature
reading.

Note:
During initial start-up the assignment of the zones must be checked. For that purpose you
should heat up the control circuits one by one and monitor the temperature rise.

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6. Specifications

Nominal Voltage: 220 to 240V AC, 50/60Hz

Nominal Capacity DPT4: 7000 W, 2 x 16A, with load on Phase L1 and L2
Nominal Capacity DPT2: 3500 W, 1 x 16A, with load on Phase L1
Stand-by Capacity : approx. 10 VA

Load Connection DPT4: 4 x heater circuit 230V / 10A,

amphenol modular connector series C146...

Load Connection DPT2: 2 x heater circuit 230V / 10A,

amphenol modular connector series C146...

Mains Plug DPT4: 3m, 16A-CEE-plug

Mains Plug DPT2: 3m, 16A-shock-proof-plug
Thermocouple Connection: Thermoelectric couple type L (FeCuNi),
amphenol modular connector series C146...
OK Output: Potential-free closing contact (max. 125V/1A not secured by
fuse)
Lowering Input: Connect a potential-free contact normally open

Fuses: FF 10A type Schurter Typ SA; superfast for Triacs

Serial Interface: Standard: RS232; optional: electrically isolated TTY, RS422,
RS485
Regulation: ″Pulsgruppensteuerung″ (Switching Power Control)
Storage Temperature: up to 70°C
Operating Temperature: up to 35°C
Protection Type: IP 20
Dimensions (W, H, D): 150mm x 150mm x 330mm
Colour: grey and blue (RAL 9018 und RAL 5015)

7. Appendices

- Appendix A
Quick Reference RET2

- Appendix B
Declaration of Conformity

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Appendix A
Quick Reference RET2

Fig. A.1 Operation Control Panel

The RET2 will be switched on by pressing the key ”1/0” (”ON/OFF”). By pressing the key
1/0 (”ON/OFF”) again, the unit is switched off. This key has no further functions.

KEY Operation Parameter Menuel Key held down

N Mode during switch-on
A count-down of parameter number
set value count-down
B count-up of parameter number
set value count-up
F Enter parameter chose next menue
Menue item
A&B Switching
between display
modes
zone 1,
zone 2,
zones 1+2
A&B Load default values
&F (standard
configuration off-
factory)
Fig. A.2 Keys: Brief Operating Instructions

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Appendix B: EG – Declaration of Conformity

For the following below listed products:

Günther-Hot Runner Controller DPT2 and DPT4

we hereby confirm, that above listed products comply to all important (*) safety
requirements that have been declared by the Council of Assimilation of Legal
Regulations by the EC membership countries concerning electromagnetical conformity
(89/336/EWG).

To verify these products to electromagnetical conformity the following standards were

referred to:

EN 50081, Part 2
EN 50082, Part 2

The above mentioned products also comply to:

DIN EN 61010, Teil 1/03.94.

This declaration applies to all above listed products with the folowing production index:

Production Index A

The production index is the number behind the serial number on the identification label
of the product. The identification label is located on the right side of the product.

DAVIDSMEYER & PAUL GmbH Elektronik

Humboldtstr.2-4
D-50181 Bedburg

Bedburg, 01.10.1997

J. Marquardt
(Managing Director)

(*) Expressions recommended by "EMV-Rechtsvorschriften und ihre Anwendung in der Praxis", Franzis-Verlag, 1993

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