Cluster MC 3800

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Cluster MC 3800

The Cluster MC 3800 modules represent the state of the art in the thermoregulation of multiple objects. And, because of its characteristics of redundancy and safety, they are the best controllers in point to point configurations when absolute reliability is imperative.

Moulds with high number of elements These modules are capable of driving up to six nozzles in complete safety
Increased reliability In moulds equipped with traditional heating elements it is possible to guarantee complete functionality in case of thermocouple failure.
Increase reliability hot runners The Cluster MC 3800 modules are capable of grouping heaters into groups: by adding a thermocouple per group these modules can assure complete reliability in the hot runners
Increased reliability nozzles These modules are capable of controlling nozzles with two thermocouples and two heating elements so as to automatically commute functionality in case of failures of any kind

Description
Functions
Specs
Solutions

The Cluster MC 3800 modules are capable of controlling to thermocouples at the same time and two power outputs. These are not two modules in one but devices specifically designed to drive redundant elements required for high reliability systems.

The main characteristics of the Cluster MC 3800 modules are:

Two independent thermocouple inputs The thermocouples can be either insulated or not, even mixed. Both inputs are protected against high tensions, like mains voltage.
Differential logical unit for the handling of the thermocouples The logical unit automatically establishes which is the best thermocouple to carry the regulation
Fast control unit capable of executing double the amount of calculations of a traditional module in just 100 ms
Oversized power unit provided with a secondary protection device capable of interrupting power supply in case of failures to the module itself and external to it.
Two power output channels each protected by it's own fuse dimensions so as to drive two heaters or group of heaters.
Heaters monitoring circuit capable of constantly measuring the power rating of the connected heaters and eventually signal any anomaly, very useful when dealing with heaters connected in parallel.

The engineering of the Cluster MC 3800 modules are the result of aggressive miniaturization that enables them to implement all of the functions that have built their reputation as problem solvers. Here is a partial list of the most important functions implemented in these modules.

Smart-PDI optimizes the regulation of small objects like micronozzles.
DS-p reduces component stress during initial warm up.
Adat-plus minimizes heaters stress during normal injection cycles.
Auto-swap automatically commutes the operational mode to manual in case of thermocouple breakdown.
xxx diagnoses in real time the status of the connected heaters.
HPM signals damages to the heaters.
LPW automatically commutes operational modes in case of damage to the thermocouples.
Off-limits allows for total quality control.
Manual operation to operate without thermocouples.

Two thermocouples inputs
Thermocouples can be insulated or not, even in mixed configurations
Available thermocouples:
- Standard Fe-Cost (J) 0 ÷ 500°C
- optional Cr-Al (K) 0 ÷ 800°C
Automatic junction compensation
Thermometric precision: ± 0.5% f.s. ± 2 digit

Thermocouples input protection up to 250Vrms continuos (normal and differential)
Thermocouples input and heaters output protected against spike
Hardware and software protection against module overheating
Mains power input protected against spikes (in the main rack)
25A rated solid state relay
Power output protected by an electromechanical relay
16 A fast fuse protection
Alarm relay (place in the rack)
All electronics reside inside the module; the rack only contains passive components that cannot malfunction. Modules are easy to replace.

3 digits display and 8 led indicators
Clear indication of operational status
Membrane keypads without knobs or switches
Non volatile settings memory

Working temperature: 5°C ÷ 45°C, non condensing humidity
Storage temperature: 0°C ÷ 50°C
Protection grade: IP20
Thermoregulators are not designed to work in environments classified as explosive as per CEI 64/4 norms

Voltage: 230V ± 10% 50/60 ± 1Hz
Internal power consumption: 4VA
Wattmeter precision: ±5%

Control of a six nozzles cluster

The Cluster MC 3800 modules completely reliable when regulating elements connected in parallel: here are some examples of common failures and how these modules solve them.

Standard modules fail in case of oper thermocouple

With the thermocouple open all nozzles in the group cool down.

The MC 3800 module continues to regulate even with an open thermocouple

If the reference thermocouple breaks, the second one takes over and production output continues normally.

With the thermocouple shorted all elements overheat

With the thermocouple shorted all elements in a group overheat, with grave consequences to mould and production output alike.

If a thermouple get shorted the other takes over and production continues normally

When the reference thermocouple gets shorted, the second thermocouple takes over and production continues normally.

If the reference heaters breaks all the others in the group overheat.

If the reference heater breaks all the others in the group overheat.

If the reference heater breaks all the others in the group continue to perate normally.

If the reference heater breaks only that one cools down while all the others in the group continue to operate normally.

Point to point regulation

The characteristics of the Cluster MC 3800 modules can also be used for efficient and unbeatable low cost point to point regulations, in a way that goes well beyond normal production continuity.