measure control automate -hot runner controller that meets

10 reasons that will convince you.

MCS - Hot runner controller that meets the highest

demands

Measure

Control

Automate

2

About Feller EngineeringINDUSTRIAL ELECTRONICS FOR MEASUREMENT AND CONTROL TECHNOLOGY

PHILOSOPHY

Founded by Erich Feller in 1972,

Feller Engineering focuses on

the research and development

of industrial electronics.

Quality, flexibility and customer

focus are the cornerstone of our

philosophy. We know how

important it is to our customers

that their requirements are

translated into functional

products.

We develop, manufacture and

distribute all of our products

ourselves.

SERVICES

Feller Engineering develops

electronic modules with a focus

on components for process

automation, such as tempe-

rature controllers and modular

multichannel temperature con-

trollers for hot runner systems,

and measurement data acqui-

sition units. Our modules con-

nect to a variety of bus systems

and also visualise processes.

Our team of experienced pro-

duct development engineers,

technicians and electro-

technicians make us a compe-

tent partner for serial products

and customer-specific solutions.

INDUSTRIES

We serve a variety of industries

ranging from plastics processing

through to machinery and

plants and cleanroom appli-

cations in medical engineering.

Typical areas of application for

temperature control are:

� Hot runners used in injection

moulding

� Automotive adhesive

assembly lines

� Extrusion, blow moulding

and injection moulding

machines

� Packing machines

� Industrial heat tapes

[email protected] +49 6074 8949 - 0www.fellereng.de

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Meeting the highest demandsCUTTING EDGE TECHNOLOGY � ROBUST � HIGHEST OPERATIONAL SAFETY

MCS hot runner controllers are the result of a

long-standing collaboration with the plastics

processing industry and over 40 years of on-going

experience in temperature controlling

technology.

Our compact controllers combine cutting edge

technology with a high level of functionality. The

controllers’ flexibility and ability to accurately

control temperatures make them suitable for

hot runners of all mmanufactures.

The controllers are extremely robust and easy to

service. Fanless operation for devices starting at

20 zones, fuses that are accessible from the

outside, optimal access to all components for

servicing and the housing’s small footprint make

the controllers unique in the industry.

The control panel and display consist of three

units: a touchscreen for optimal handling and

parameterisation, function keys to quickly select

commands and an additional separate display for

each of the zones that is easy to read from a

distance. This offers the highest level of

operational safety and user friendliness.

Customers can choose from 6 housing sizes,

enabling them to create 2 to 128 control loops

with one device. The controllers can be combined

to expand the number of zones in such a way

that the whole unit works as one controller.

Unique LED strips that are clearly visible from any

angle - even at a distance - indicate the different

operating modes.

Internally, the controllers have a modular

configuration, enabling them to be completely

integrated in the injection molding machine and

thus operated from the machines´s control panel.

MCSr128MCS8 MCS16 MCS32 MCS64 MCSr96

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PULSED MODE

Output rate = 25%

At a higher output rate, pulsed mode produces the better control behaviour.

The voltage switches at the zero-crossing point, which, among other things,

reduces the wear on the heater.

Innovative control algorithms based on over 40

years of experience in temperature control

technology are the basis of accurate and robust

temperature controls. This means that MCS hot

runner controllers can be used with any hot

runner in the market.

Particularly noteworthy is the special heater

control. Voltage impulses are rapidly emitted (up

to 100 times per second) so that changes to the

control behaviour can be dealt with quickly. This

fast reaction time enables even the smallest of

nozzles to be accurately controlled.

The controllers also have the flexibility to adapt to

highly sensitive processes. Each zone can be

operated separately in pulse mode, with phase-

fired control or in mixed mode. Based on the

output rate, one of the methods will deliver the

better control behaviour. MCS hot runner

controllers switch automatically between both

operating modes.

YOUR BENEFITS

� High control accuracy

� High operating safety

� Robust temperature controller

� Flexible for hot runners of all

manufacturers

PHASE-FIRED CONTROL

Output rate = 10%

At a lower output rate, phase-fired control produces the better control

behaviour. The voltage impulses are small and rapidly emitted in intervals of

10ms.

10ms 10ms

Accurate and robust temperature controller

10 REASONS THAT WILL CONVINCE YOU

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Unique operating and display concept


Red indicates faults or

temperature limits

that have been

exceeded.

The outputs are

deactivated.

MCS hot runner controllers have a

touchscreen for parameterisation

and operation as well as a separate

display for all zones.

This concept is unique and has two

advantages: optimal operation and

parameterisation from the touch-

screen and a very easy to read

display, even from a distance, of a

zone’s current values.

The user can switch between set-

point, actual value, deviations,

output rate and heating current at

the press of a key.

Function keys provide quick access

to special commands without having

to select them on the touchscreen.

A three-sided LED strip indicates the

operating mode and is clearly visible

from a distance.

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YOUR BENEFITS

� Intuitive touchscreen operation and parameterisation

� Separate, switchable display for all zones

� Optimal visibility of all zone values and operating modes – even from a distance

� Function keys to quickly select commands

Green indicates that

everything is OK. The

controller is operating

normally.

Yellow indicates non-

critical deviations from

normal operation.

Separate display for all zones

LED strip displays the status

Touchscreen

operation

Function keys

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Maximum power with 16A for all zones


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Each of the MCS hot runner controller's outputs

can deliver up to 3,6kW. The outputs for nozzles

and distributors do not have to be specifically

assigned. This makes MCS controllers highly

flexible and usable with different hot runner

systems.

The maximum heating current of 16A is also

guaranteed at higher temperatures inside the

device by the robust wiring and conductor cross

sections. Moreover, only plug contacts are used

that are also designed to handle 16A at high

temperatures.

Individual zones up to 8kW (35A) can also be

equipped with plug connectors.

YOUR BENEFITS

� Highest operating safety even at higher

operating temperatures

� Maximum flexibility in the assignment of

the nozzle and manifold outputs

� Customisations for higher outputs are possible

3,6kW / zone

� 11kW / 16A CEE

� 22kW / 32A CEE

� 43kW / 63A CEE

� 86kW / 125A CEE

Total output Individual output up to 16A


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Comprehensive monitoring functions


MCS hot runner controllers have extensive

monitoring functions to protect tools, hot runners

and controllers.

All of the functions and parameters that are

relevant to the injection process are constantly

monitored and indicated in the event of a failure.

This includes monitoring the wiring for reversed

polarity, breakages and short circuits. If a sensor

fails, the affected zone can be operated manually

or as the slave of an adjacent zone.

The leakage current monitor has an intelligent dry-

out routine that limits the temperature in the

event of residual moisture or insulation problems,

preventing short circuits.

The output rate monitor detects irregularities in

the heating behaviour, e.g., in the event of a

leaking nozzle. Defective fuses, heaters and triacs

are also detected.

In addition to the monitoring functions that are

active in normal operation, zone or group-depen-

dent diagnostics can also be run. This function is

particularly useful after commissioning or

installation work and it reliably detects incorrectly

assigned heaters and sensors.

Sensor fault/short circuit/reversed polarity

Output rate

Leakage current

Heater

Fuse

Triac

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YOUR BENEFITS

� High operating safety to protect tools,

hot runners and controllers

COMPREHENSIVE MONITORING FUNCTIONS

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220

180

-H-

Zone 10

Setpoint [°C]

Actual value [°C]

?

Zone Group All Zones

Troubleshooting for rapid fault location


MCS hot runner controllers have an integrated

troubleshooter that helps users locate and resolve

faults.

All the user has to do is select the faulty zone on

the touchscreen. The faulty zone is also clearly

visible in each of the zone's separate displays. The

fault code that displays on the screen enables

users to immediately identify the cause of the

problem. A full description of the fault is available

by activating the troubleshooter, which also

provides useful information on resolving the fault.

Downtime is reduced to a minimum.

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5

YOUR BENEFITS

� Very short downtimes in the event of a

failure

� Clear information on the potential cause

of the fault and its resolution

1. Zone indicator flashes in the event of a

failure

1

2. Activate the fault zone

3

Activate the

troubleshooter

Troubleshooter with

information on locating and resolving faults

4

2


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Mobile control and diagnostics station


MCScontrol is the optional, user-

friendly touchscreen control and

diagnostic station for the MCS hot

runner controller.

All of the temperatures are

periodically archived on the

integrated hard disk and can be

displayed as a curve chart over a

number of days. This enables users

to analyse and optimise the process.

The process overview displays tools

as a graphic that includes

measurements. The user can control

a zone simply by touching the

corresponding measurement. This

results in a high level of user

friendliness and safety when

defining temperature values.

The Fault Statistics function

automatically focuses on zones with

a high fault frequency. One glance is

all that is needed to check the

continuous process over several

hours and identify the faulty zones.

Temperature curves

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YOUR BENEFITS

� Graphical display of temperatures over a period of multiple days

(historic trending)

� Intuitive operation with graphical tool display

� Comprehensive tool diagnostics with protocol

� Remote use (up to 100 metres)

� Can be used as a mobile diagnostics station with devices with integrated touchscreen Graphical display of the tool

Diagnostics protocol

The integrated tool diagnostics

check the connected heaters and

sensors. A comprehensive protocol

with information on resolving the

fault is created. Notes can be added

to the protocol and it can even be

printed. The protocol provides a

detailed picture of deviating heating

behaviour and enables decisions to

be made on changing the hot

runner.

MCScontrol

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Service-friendly Design


Users can perform the most important service

work on MCS hot runner controllers themselves

such as the replacement of fuses on the output

side. The fuses are at the back of the devices and

accessible from the outside, meaning that the

controllers do not have to be opened and the

fuses can be replaced without requiring any

special technical knowledge.

Users can also replace the triacs in the event that

the outputs' power electronics are damaged by a

short circuit. This prevents expensive repairs and

downtime. Fuses and triacs are delivered standard

with the hot runner controller as part of the spares

package.

Our worldwide agents can help with more

complex service issues. For a current list of our

agents, see www. fellereng.de.

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External cooling units

Fuses are accessible from the outside of

the device

Exchangeable triacs

Compact power unit with cooling unit and

power electronics

YOUR BENEFITS

� Low downtime

� Low repair costs

� No special knowledge required to replace fuses

� Worldwide support


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Flexible extension of the number of zones


MCS hot runner controllers enable several

controllers to be combined and operated as one

control unit. This flexibility enables you to expand

the number of control zones in applications where

one controller is not enough without having to

invest in a new and bigger controller.

Data is exchanged between the controllers

through a CAN bus.

The combined controllers work as one controller.

For example, you can operate all of the zones from

the master. Alarms and notifications are also

synchronised. Higher level functions, such as

group heating, are combined across all devices

into one function.

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Bus connection

MCS16= +

YOUR BENEFITS

� Flexible expansion of the number of

zones with smaller standard devices

� Combined controllers work as one

controller

� Centralised operation

� Continuous number of zones

� Synchronised alarms across all

systems

MCS321 control device with 48 zones

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Easy machine integration


The modular design of the MCS hot runner

controller enables all of its components to be

integrated in the injection molding machine. The

controller is operated and visualised from the

machine's control panel.

The controllers are internally divided into modules

such as processors, temperature measurement,

power electronics etc. and are easy to integrate in

standard control cabinets.

Their small footprint provides for a narrower

equipment grid.

The ability to integrate the controllers in machines

is a huge benefit in particular for applications with

high hygiene requirements (e.g., cleanroom

applications in medical engineering). The number

of zones can be expanded at any time by

connecting an external MCS standard controller.

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YOUR BENEFITS

� Small footprint

� Easy to integrate the hot runner control module in standard control cabinets

� Meets hygiene requirements for

cleanroom applications

� Number of zones can be expanded with

standard controllers

Modular hot runner controller components

integrated in injection molding machine

Hot runner controller can be operated from the

machine´s control panel


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„… We've been working with Feller Engineering

GmbH for over two decades and have come to

know them as an extremely reliable and

competent business partner…“

Satisfied customers


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„… The device's service friendliness and the

great support are why we'll continue to use

Feller.“

M+C SCHIFFER GMBH

„… Feller is a great partner, especially when it

comes to finding special solutions for the most

extreme requirements…“

WEIßER + GRIEßHABER GMBHAGRODUR GROSALSKI GMBH & CO. KG

We have been using Feller Engineering's MCS controllers since

we started our own injection moulding factory.

They're extremely reliable and their control quality is excellent,

which is why we have made them our factory standard.

FRESENIUS Medical Care Deutschland GmbH

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The Auto-Power function enables controlled continued heating in the event

of a sensor failure thereby reducing production downtime.

Several zones can be combined into groups and parameterised as one. This

facilitates commissioning.

GROUPING

The sensor inputs are protected against power surges by a fuse stage. The

pluggable fuses can be quickly and inexpensively replaced in the event of a

failure.

MAINS VOLTAGE PROTECTION FOR SENSOR INPUTS

Cold zones are slowly heated without impacting the slower zones. This

preserves the nozzles and material and prevents a thermal imbalance from

occurring in the hot runner system

GROUP HEATING

Zones can be grouped and sequentially heated up, creating a clean seal on

the nozzle tip. Controlled cooling is also possible.

SEQUENTIAL HEATING AND COOLING

A lot of other functions included

SIMPLY CONVINCING.

CONTROLLED CONTINUED HEATING IN CASE OF A SENSOR FAILURE

Digital control inputs are used to select injection moulding recipes or activate

control commands such as Release and Standby. The alarm contacts enable

centralised monitoring.

CONTROL INPUTS OUT OUTPUTS

The tool storage stores the configuration data for all of the zones. This saves

time and prevents input errors when the machine is restarted after a tool

change.

TOOL STORAGE

All of the zones can be diagnosed to make sure they're working properly. The

detection of inverted or reversed wiring, for example, increases operational

safety.

AVAILABLE DIAGNOSTICS

The Softstart function gently heats up the elements by limiting the power

based on the temperature.

GENTLE HEATING

We deliver the right model for every standard.

CUSTOMER-SPECIFIC PLUG-IN CONNECTORS


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Technical Data

SIMPLY CONVINCING.

OPERATING VOLTAGESwitchable

Tolerance

3x 380-400VAC, N, PE /

3x 220-230VAC, PE

+ / - 10%

POWER CONSUMPTION Idle max. 70W

FUSE OUTPUTS Heat outputs external

Additional fuses internal

each 16A gRL (6,3 x 32mm)

each 16A inert (6,3 x 32mm)

THERMOCOUPLE-INPUTS Fe-CuNi Type J / NiCr-Ni Type K - parameterisable 0..700°C

Reference point compensation internal

Temperature measurement accuracy 0,1K

CONTROLLER-OUTPUTS Bistable, electrical isolated, per zone 1x heating, 230VAC switching

Shortest controller reaction 10ms at 50Hz

Current per zone max. 16A (standard version)

Note: Always observe the total capacity of the mains!

ALARM-OUTPUTS Functions 1x alarm contact and 1x warning contact

RELAY-CONTACTS max. voltage 250VAC

max. current 4A at cosϕ = 1 / 2A at cosϕ = 0,5

CONTROL-BEHAVIOUR PI, PD or PID for all zones separately adjustable Self-adaption of the control parameters

INTERFACE galvanically isolated

RS485, protocol FE3-Bus / Modbus / Euromap / Arburg

CAN-Bus

AMBIENT CONDITIONS Working temperature

range Protection type

0..50°C

IP 20

Housing surface temperature max. 55°C

Storage temperature -25..+75 °C

Humidity < 95% rel. humidity, no drop

WEIGHT / DIMENSIONS WXHXD MCS® 8 / 16 12 / 16kg - 24 / 40 x 21 x 37cm

MCS® 32 25kg - 45 x 28 x 43cm

MCS® 64 / 96 / 128 75 / 90 / 110kg - 50 x 80 / 100 / 120 x 50cm

MCS®rxxx Lower height of 8 cm compared with other standard devices.

Simply convincing

Measure

Control

Automate

measure control automate -hot runner controller that meets

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