...of hot runner controllers
...from PMS Systems
“Better by Design....”
Today’s demanding moulding applications require a hot runner
controller that you can rely on for precision control, ease of use
and day to day reliability. Equipment size is also an important
issue when trying to maximize shop floor utilization. With this in
mind PMS have produced the K-Series range of controllers.
Designed from the ground up, employing the latest surface
mount technology, colour touch screen consoles and using the
know how that PMS have acquired over the last two decades of
making computer based controllers.
The K-Series of modular controllers are amazingly compact
and very economical, especially on high zone counts. There
are several control card options available, either with or without
current measurement - with a 6 x 5A, 3 x 15A, 2 x 20A and 1 x
30A output zones. Cards can be factory fitted in any
combination to suit the application. Cabinets are available in
various sizes - 5, 10, 20, 30 and
40 slot, which can run up to a
maximum of 30, 60, 120,
180 and 240 zones respectively.
They have been designed with a cassette
construction, which fits into an outside shell,
making them suitable for mounting into a machine
cabinet, for even greater system integration. The
robust cabinet designs have an interlocked card
access door and include current and earth leakage
trips for maximum mould safety. Larger cabinets
also have a rear access door. Control board LED
indicators are visible through the front door window
Exploded CAD view of a modular K20 cabinet,
for up to 120 zones, showing the simple cassette construction
“..with a range of control cards
to suit every application ”
The K-Series design allows for a variety of configurations, using a selection of
plug-in cards that perform the temperature control function. The all-in-one
modular design includes the complete control circuitry, making servicing far
simpler. 6 zone 5A cards, designed for probe zones, offer the most in terms of
reduced cabinet size and cost, typically reducing the cabinet volume to less than
a third that of earlier models. Higher current output cards are fitted for manifold
zones. Moulders who prefer to have the flexibility of high current on all zones can
choose to fit the 3 zone 15A or 2 zone 20A cards throughout. There’s also a 1
zone 30A card for those heavy duty applications. Whichever card you choose, the
use of modern surface mount electronics, makes them considerably more
compact than conventional designs. The powerful CPU on each card affords the
controller the luxury of being able to switch between Time Proportioned or Phase
Angle Fired modes when required, giving greater heater protection during startup
bake out and superior control of small sensitive probes. All cards are fitted with
two rail heater output and T/C input fusing, for maximum protection.
We also offer a special 4 zone card designed for thermal gate control of low
voltage probes with a 32v body and an 11v cycle synchronized tip zone.
K5 K10 K20 K30 K40
Available card slots 5 10 20 30 40
Maximum zones (using 6 zone cards) 30 60 120 180 240
Typical max. Probes & Manifolds 24+3 48+6 96+12 144+18 192+24
Mounting Desk Floor Floor Floor Floor
Optional trolley available T - - - -
Optional Alarm/Beacon available T T T T T
Optional input/output signaling card T T T T T
Cabinet only dimensions, cm 48w x 46d x 28h 39w x 27d x 65h 46w x 40d x 80h 46w x 40d x 102h 46w x 40d x 121h
Outside dims incl Castors (no screen) n/a 49w x 41d x 91h 58w x 52d x 98h 58w x 52d x 120h 58w x 52d x 139h
Internal cooling fans 1 x 120mm 4 x 80mm 5 x 80mm 8 x 80mm 10 x 80mm
IP54/NEMA12 sealed cabinet - T T T T
Card access door via interlock & key - T T T T
Key access rear door - - T T T
Key access to cards via hinged lid T - - - -
Includes integral MTS touch screen T - - - -
Disconnecting heavy duty connectors T T T T T
Standard cable length (extra optional) 3m 3m 3m 3m 3m
K-Series controller cabinets are very robust and use minimal floor space. A major advantage of the
modular design is that all the control electronics are mounted on the plug in cards, which can be
easily removed or swapped around in seconds, if it becomes necessary to diagnose a problem.
The cabinet itself only contains a small power supply - the rest is wiring and supply. All cabinets are
built with ease of maintenance in mind, with easy access doors, cable numbering and wire end
ferrules throughout. Each cabinet includes a machine input and alarm output connector as
standard. The cabinets are air cooled, with enough filtered forced air to handle the heaviest of
loads. Trolley wheels with front brakes and anti-tilt cast mountings complete the package.
Display Console Models...
PMS offer a range user interface consoles, from budget
level to fully featured, all with the same look and feel
software style. All consoles incorporate colour touch
screens and modern PC technology, offering the user the
most practical and intuitive interface to the moulding
process. Consoles can be mounted on the control cabinet
or remote to the cabinet via a serial data cable.
Model features... MTS KTS TSA TSN TSL
Screen size, diagonal 5.4” 8.4” 12.1” 12.1” 15”
Maximum zones 60 60 240 240 500
Resolution, pixels 320 x 240 800 x 600 800 x 600 800 x 600 1024 x 768
Main display modes, zones per page 20, 40, 60 40, 70 40, 70, 110, 160 40, 70, 110, 160 60, 108, 168, 252
2D multi-zone graph T - - - -
3D perspective multi-zone graph - T T T T
Maximum zones per graph 6 20 20 20 20
Easyview layout display page - T T T T
Support arm mountable - - - T -
IP54/NEMA12 sealed case - - - T -
Drawing/picture store - T T T T
Network connection, Ethernet RJ45 T Optional wireless T T T
Event/alarm logging database - T T T T
Export historical data to PC, max 30 mins 24 hrs 24 hrs 24 hrs 24 hrs
Max number of tool settings stored 100 200 200 200 200
Removable media (export/ upgrades) USB memory USB memory USB memory/ floppy USB memory/ floppy USB memory/ floppy
Software & settings are stored in... Flash memory Compact flash card 2.5” hard disk 2.5” hard disk 2.5” hard disk
Printer port connection USB USB USB USB USB
Max size including any handles, cm 36w x 14d x 23h 48w x 19d x 28h 38w x 19d x 37h 60w x 20d x 35h 42w x 21d x 39h
The table above show the differences between the various models, but there is much more that is
common across the range. All screens have the same basic operation, for small and large systems
alike. Even the base MTS model has all the operating modes and setting flexibility of the larger
systems, with many advanced features to help you really take control of the moulding process. The
user touch screen interface program runs inside a hidden Linux operating system, which offers
industrial robustness and advanced networking capabilities. All models have common mechanical
fixing points and electrical connections to the cabinet, making them fully interchangeable.
Touch Screen Control
Operator usability moves into a higher plane with the release of the latest PMS touch screen software. It brings
together the latest in Pentium powered PC technology and everything we know about hot runner control.
Designed for maximum flexibility, using a Linux operating system and X-Windows, the console comes network
ready as standard, giving it the capability to be operated and supported remotely if required.
Colour coded keypad
Status bar Help pages
PMS has built a reputation on the simplicity of its user interface software. This philosophy follows
through to the touch screen console with point and set control modules, touch and rotate 3D
perspective graphs and page selection tabs. Realistic looking needle deviation meters on each panel
echo back to earlier technology, visual prompts that
Zone identifier or alias
everyone can easily identify with at first glance.
Actual temperature or fault message
Selection buttons look 3D and move as you press
Temperature set point
them. The user does not have to learn an operating
Power output level - Amps or %
syntax, just point at the selection you want.
Deviation from set point
“ Making settings
is as easy as
At the core of the program operation is the ability to quickly make settings, and
view the results. This operation couldn’t be simpler. Just touch the zones you
wish to change, touch the set button, then enter the new value with the
keypad. Several zones can be selected at once, if required. There is also a
range button for selecting groups, rows or all zones at once.
1 Select the zones
you wish to change 2 Press the
Set button 3 Enter a
The same simple operation is used to add or subtract values. This can be very
useful, on start up for example, for adjusting a range of balanced settings up or
down, without losing the relationship between values. The setting keypad also has
mode selection for operating in one of three modes:
Auto - Normal closed loop operation using set temperatures.
Manual - Open loop operation using power values.
Slave - In the event of thermocouple failure the controller can mimic the
output of a similar closed loop zone, selected either manually or
automatically to continue moulding seamlessly.
Additional buttons are available for turning zones off or boosting
selected probes. If the software has been configured for running cycle
synchronized thermal gate probes, an additional button is displayed for
setting tip boost parameters from the entry keypad in the same way.
Above all, the human interface has been designed to be as intuitive and simple to
use as possible. Even the first time user can quickly get results.
“ More control,
less effort... ”
Interactive 3D Graphing
One of the most astonishing features of the PMS touch
software is the 3D graph page. It shows an auto ranging
tape graph to represent and compare up to twenty control
zones in 3D with perspective. What’s even more amazing
is that you can touch and smoothly rotate the graph, multi-
axis, in real time. This allows you to get a better view and
understanding of the temperature changes inside the tool.
Data plots are constantly updated and flagged with the
zone identifier or alias name. Control buttons allow you to
increment the displayed zone numbers and change the
graph time base. The Timeline feature also gives you the
ability to look back over the last 24 hours of recorded
Zoom in for more detail
The Zoom button displays a more detailed view of any user
selected control zone. The zoomed-in view contains two
further 3D perspective graphs, which can also be smoothly
rotated for a better view. The deviation graph shows the
minimum and maximum deviation from set point during a
sample period. Like the main graph, the program auto
scales the data to fit the lowest and highest values,
allowing an excellent view of both the startup curve and
control stability at set point. The second graph monitors
power output to the zone. Control buttons increment the
displayed zone number and change the graph time base.
Easyview picture page
One of the most useful features of the system is the ability to
store bitmap images. This offers a convenient method of
storing associated circuits, diagrams or product pictures,
always available at the moulding cell. In addition the Easyview
feature allow you to move live temperature mini-panels onto
any picture, drawing or sketch. This offers major benefits in
terms of layout awareness when making setting changes or
diagnosing a problem in the mould. For convenience,
temperatures can be set directly from the Easyview screen.
The panels are placed on the image by touch, drag and drop
from a list of zones. The mini panels can be switched to show
the process temperature, set point, power output or deviation.
The Setup page
Designed in a spreadsheet format, the setup page allows the
user to quickly make settings individually by zone, for a number
of variables, offering full setting flexibility. The software initially
scans the control cards in the cabinet and places a picture of
the installed cards on the screen. Zones are selected for editing
and set in a similar way to the main screen operation, quickly
and simply. Other global settings are available in the Config sub
menu. All value changes on the Setup page require the high
level password, unless disabled by choice. Zone aliasing can
be used to rename the hot runner zones in a more
understandable format, for cavity number identification etc.
Once set, the complete configuration can be saved in the
Toolstore or backed up to floppy disk or USB media.
MTS Software Version
The MTS touch screen has been designed to follow the same style of
operation, and retains almost all the setting capabilities of the bigger TS
software. The quarter VGA screen does not support Easyview or 3D
graphing but does have excellent 2D graphing for up to six zones. Using
the full capabilities of the touch screen, graphs can be zoomed and
scrolled to get a better view of the control performance. MTS offers much
of the functionality and features of our best system, at a budget price.
The MTS screen is available either as a remote display or as a built in
display on the K5 models. Continuity of software design and features
across the complete range of controllers reduces the need for training
and substantially improves the ease of use.
Features & functions in detail...
Operating Modes - The system includes various modes of hot control for
starting and stopping the heating process. Available on the main display
page the modes are…
Stop - all power outputs set at zero, but set points can be adjusted.
Startup - uses various start-up methods, previously configured in the Setup
page, to bring all hot runner zones to set point.
Manifolds only - This heats the manifold zones close to setpoint before
bringing up the probe zones. It allows for expansion of the hot runner
system in the x-axis before expanding the probes in the y-axis, thus
reducing long term wear of the hot runner components, and reducing the
possibility of material degradation.
Follow Manifolds - In this mode the probes track the slower moving manifold
zones to the set point, automatically switching to Run mode once set point
is reached, again reducing component wear and material degradation.
Staged Startup - For more complex hot runner designs, it may be desirable to
start the groups of zones in sequence. Example, heat the bridge manifold
first, then satellite manifolds then probes. Staged Startup allows this,
configured in the Setup page for up to 9 groups.
Fully functional mimic screen working in Windows XP using X-Win Boost - This mode temporarily increases the set points of all zones, for a user
defined boost time period. Boost values can be individually set by zone in the
Setup page. For example it may be desirable to boost only probe zones,
Main Display Screen - features panel re-sizing, giving the option of
some more than others. It's fully flexible. Tip Boost - Individual zones can also
either detailed zone information or progressively more condensed panels to
be boosted from the main display page.
show more zones per page, up to 252 on our biggest console. Each panel
displays Set, Actual, Power (either % or Amps) and deviation (not MTS). Red, Standby - This reduces set points, typically below the material melting point,
yellow and green colour signaling for Alarm, Warning or Normal conditions in the event of a pause in production, to prevent material degradation. Again
respectively on each panel easily show the controller status at a distance. By the standby values can be set individually by zone in the Setup page. For
fitting various optional signal cards in the cabinet the screen can be example, it may be desirable to reduce the probes to a lower temperature
configured with colour coded panels to show other data including water flow, than the manifolds to allow for a fast restart.
steel/water temperature, pressure or chiller temperatures. A page print Run - Normal running mode. All zones follow their individual set points.
function is available for output to a colour printer.
Shutdown - This is the reverse of the Startup mode. It brings the temperature
3D graphing (not MTS) - The graph page show a 3D perspective tape of the hot runner system down uniformly across all zones, rather than just
graph for up to 20 zones, selected in any order against a 5 or 30 minute time switching off. This can also reduce component wear long term.
scale. The graph can be smoothly rotated by touch and drag for the best Tool Store - The system has the ability to store up to 200 mould setups
view. The data is constantly updated and auto scaled to fit the plot. There are
(100 for MTS). These setup files can be backed up or transferred to other
page up/down buttons that allow you to scroll through the zones and a print
controllers via floppy disk or USB media. Settings in the Tool Store page also
button that produces a coloured plot output in the resolution of your printer.
allow for connecting to another controller via an Ethernet connection. It's
In addition the Timeline function displays the same 5 or 30 minute graphs
possible for one touch screen to be used for controlling several slave
using data recorded over the last 24 running hours. You can scroll back over
cabinets via a wired or wireless connection.
time or select a particular time segment from a list.
Utilities Menu - This page contains various useful functions…
2D graphing (MTS only) - The graph page show a 2D line graph with
coloured plots for up to 6 zones, selected in any order. There are page Event log - Every setting change of any kind, alarm status change or any
up/down buttons that allow you to scroll through the zones and a print button other event of consequence is logged in a database. This can be searched in
that produces a coloured plot output in the resolution of your printer. The various ways to look back in time in the event of a problem. You can search
graph can be manually scaled in both the X and Y axis, to zoom into a more by zone, event or setting variable.
detailed view, which can then be scrolled around with touch and drag. Data Export - Recorded temperature measurements, deviation and power
output values can be exported in CSV file format (comma separated variable)
Zoom Page - For greater detail the zoom page shows all information and
to your PC spreadsheet, database or QA program via floppy disk, USB media
settings for any single selected zone. There are also two additional 3D
or network connection. Data can be selected by range of zones and
graphs displayed on the page (not MTS), deviation and % power output,
time/date span for up to 24 hours (MTS does 30mins).
available in 5 and 30 minute auto scaling plots.
Network settings - Setup the console network settings for either fixed IP or
Picture Store (not MTS) - Drawings, photos or documents are stored in automatic using DNS.
bitmap format for display in the picture store viewer. Other file formats can be
Printer settings - Most printers are catered for by selecting the appropriate
easily converted if required. Large images can be scrolled around the screen
driver from a list.
using touch and drag. A large thumbnail picture and image description is
shown with each file entry for quick reference. Pictures are loaded from or Password setting - There is a two level password system. The user password
backed up to floppy disk or USB media. allows day to day setting of process variables, running modes, tool loading
and various page displays. The System password allows additional setting
Easyview (not MTS) - An option button in the Picture Store links any
capability in the Setup page for process limits, alarm limits and other
selected image with the current running tool setup. This relationship is then
sensitive settings. Both passwords are editable and can be disabled if
also stored in the tool store for future use. Once the link is made the user can
required using the System password. Note: PMS also has a secret password
place live mini panels onto a photo, drawing or sketch of the hot runner or
that can be called upon in the event of the passwords being lost or forgotten.
cavity layout, placing or moving them by touch and drag from a list of zone
names. On the Easyview page the live panels can be set to display various Time and Date - Set the system clock.
process variables. Setting changes can be made directly from the Easyview Upgrade - The system software has the ability to be upgraded if required
page using a similar select and set method, as used throughout the without stopping the moulding process, via either floppy disk or USB media.
software. A print option outputs the image with mini panels displayed.
Testing Page - The touch screen has a diagnostics feature, which Allow Tool load - Enable/disable tool settings to be loaded when in Run mode.
allows the mould to be fully tested for various wiring or component faults. Blanking Delay - Screen saver timeout.
Testing is done sequentially across a user specified range of zones,
Boost Time - Duration of Boost mode in seconds.
applying small amounts of power to each zone and looking for a
corresponding temperature rise. The system also measures the current Deferred alarm mode - Delay an alarm event by up to 999 seconds.
passing in each zone and compares it with previously recorded values to Help pages - A comprehensive on-screen manual is always available
pre-warn the user of a possible failing heater. Test passes or failures, including a Trouble shooting section, Glossary and helpful “How do I…” index.
including crossed wired zones, cross linked zones or other wiring faults
are listed in a plain English report that can be printed if required. Communication - The console has several methods available for
communication between devices…
Setup Page - This page allows the user to configure the controller for
SPI server - Plastics industry standard for serial communication of settings
the current application, or saved Tool Store files, using the System level
and control data.
password if enabled. The spreadsheet style page has several variables
that can be edited individually by zone, range or group… Modbus server - Serial communication protocol for transmission of settings
and control data.
Alias - Every zone can be given a name that displays throughout the
software that relates more to the user. Examples, Cavity 47, L/Bracket, VNC server - Allows the user to run a mimic control screen on a remote PC via
Sprue etc. a network.
T/C open - What to do with this zone/zones if the T/C fails. You can select X-Windows server - Run one or more mimic control screens on remote PC's
the following options… via a network.
Normal - Signal a fault and shut down power Data Exchange server - Exchange live data from the touch screen directly into
your Windows application in real time via a network.
Auto Man - Use a percentage power calculated from historical averages
and automatically continue moulding seamlessly. HTTP server - Access control data using you web browser via a network.
Auto Slave - Slave to a similar computer selected zone, duplicating the Signalling - K-Series controls come with input/output ability as standard.
output power and automatically continue moulding seamlessly.
Machine signal Input - All touch screens in the range include a signal input for
Slave - Manually pre-define which zone to slave to in the event of a connection to the moulding machine. The software can be configured to use
failure and automatically continue moulding seamlessly. this signal in various ways for switching modes to Boost, Standby or delayed
Standby - Set by zone, range or group the Standby drop in temperature. Auto Standby. The input is also used for thermal gate control systems for cycle
Boost - Set by zone, range or group the Boost increase in temperature.
Alarm output - Every K-Series cabinet has an alarm output connector with
Master - Defines the manifold zone for each zone, range or group of
voltage free contacts for machine signalling.
probes to follow in Startup mode.
Optional Cards - To further enhance the capabilities of the controller there
Warning High/Low - Set the deviation limits before the warning status is
displayed. are several special cards and other items available…
Alarm High/Low - Set the deviation limits before the Alarm status is HRC-IO3 - I/O card with 4 inputs, 4 outputs. Includes injection disable function
displayed and alarm signalling is triggered. and remote mode switching of the controller from the machine.
Maximum Temperature - You can pre-define the maximum temperature HRC-WT3 - 12 zone resistive sensor RTD input card. Used for steel and water
an operator with the User password is allowed to enter. If a value entered circuit temperature measurement.
exceeds the limit, then a warning is displayed and the upper limit is used HRC-AI - 8 zone analogue input card for 4-20mA sensors. Used for water flow
as set point. and pressure measurement.
Maximum Power - Upper limit power setting when working in open loop HRC-DI - 8 zone digital input card. Used with turbine flow sensors. Includes 8
mode. additional signal inputs.
Display Group - The main display can be configured in several ways to HRC-AB - alarm tower with integral sounder and sounder disable keyswitch.
group zones into multiple pages. Each zone is given a group page HRC-KT - Optional trolley for the K5 desk mounting model.
number for the zone to display in.
Control Cards - Standard versions are 6MODC - 6 zone x 5A, 3MODC - 3
Staged Startup/Shutdown - Each zone can be allotted a group number
zone x 15A, 2MODC - 2 zone x 20A and 1MODC - 1 zone x 30A. There is also
when using the staged start up and shutdown. Groups of zones then heat
a special card available, the 4SMOD, for Thermal gate control of 2 x two zone,
up sequentially, one group after the other.
cycle synchronized probes.
Speed - The control cards use an auto-tune system to determine what
T/C fusing - 62mA nano fuses in both legs.
kind of load is attached to the output. However it is possible to manually
override the automatic settings if required. Power fusing - Suitably rated FF semi-conductor fuses in both legs.
T/C offset - It is desirable in certain circumstances to adjust the display of Range - 0-470C, 32-880F.
measured temperatures to enable a more accurate representation of the Control Method - Phase angle or time-proportioned firing
actual melt temperature in some combined heater and T/C formats, where
Environment - 0-50C, 32-120F: Humidity <90% non-condensing.
accurate offset values are known.
Frequency - 50 or 60 Hz, automatic switching.
Cycle Sync - For hot runner systems using thermal gate control there are
additional variables to be set for timings and power output. Card dimensions - Eurocard 220 x 160mm, 4HP pitch.
Temperature display resolution - 1C, 1F. For RTD’s 0.1C, 0.1F
Config Page - This section allows the user to display and edit settings
that relate to the whole system. Temperature readings per second - 100 per zone.
Language - Includes English, German, French, Spanish, Portuguese, Isolation - The low voltage electronics is 100% optically isolated from the
Polish and Chinese. Language can be changed on the fly. mains voltage circuits.
Temperature Scale - C or F can be changed on the fly. LEDs - Indicators visible through the cabinet door - Scan, T/C fault, Fuse Fault
and Load indication for all zones.
Console Startup - Switch on in Stop, Startup, Standby or Run mode.
Calibration - Via built in software routine and T/C calibration device.
Auto Standby mode - Using a cycle signal, automatically go into Standby
mode if the moulding machine has been stopped for more than a pre- Certification - CE tested and marked, certificate available on request.
defined Auto Standby Time to prevent material degradation. Cabinet supply voltage - 380-440v 3 phase Star, or 200-240v 3 phase Delta.
PMS Systems Limited
Rotherwas Ind. Est.
Hereford HR2 6JU
Tel: +44 (0)1432 265768
Fax: +44 (0)1432 263782