13.2 Warnings and measures

Warnings do not interrupt the operation of the device, but require the attention of the operator. For some warnings, measures can be defined that are automatically applied during operation (without immediate user intervention). More on this in Section 9.1, “Channel settings” (channel settings/temperature sensor/on error…) . To acknowledge warnings or errors, the OFF button must be pressed and the following dialog confirmed.

Warnings – clear by themselves

WRN-00 Lower limit of current range

Cause: The set lower current limit is undershot – broken heater?
Measure: Check the heating circuit. What the current limits mean is described in Section 6.7, “Current monitoring”; the automatic reaction can be set under Section 9.1.5, “Current”.

WRN-01 Upper limit of current range

Cause: The set upper current limit is exceeded – short circuit in the heater?
Measure: Check the heating circuit, see Section 6.7, “Current monitoring”. The automatic reaction can be set under Section 9.1.5, “Current”.

WRN-02 Phase

Cause: Phase loss – all channels of the device on this phase are out of sync.
Measure: Check the building-side fuse of the supply and the supply line for cable breakage. How the Thermonom distinguishes phase and mains failure is described in Section 6.10, “Groups, substitution and failures”.

WRN-03 Fuse

Cause: The phase is present at the device but only this channel does not see it – the miniature fuse of the channel is defective.
Measure: Replace the miniature fuse of the channel board with the same type (16 A, fast acting). For instructions see Section 15.1, “Channel fine fuse”.

WRN-04 Lower temperature limit

Cause: The actual temperature is below the setpoint by more than the warning limit.
Measure: Normal while heating up. During operation: check the control parameters and repeat the tuning, or adjust the warning limit. What the warning band means is described in Section 6.6, “Temperature monitoring”.

WRN-05 Upper temperature limit

Cause: The actual temperature is above the setpoint by more than the warning limit.
Measure: Check the control parameters and repeat the tuning, or adjust the warning limit. At a low output level the warning indicates heat input from outside, see Section 6.6, “Temperature monitoring”.

WRN-06 No load

Cause: The channel is switched on but no load is detected.
Measure: Check whether the hot runner is connected and whether there is a cable break.

WRN-07 Sensor break

Cause: The sensor is measured with too high a resistance – no continuous measuring circuit.
Measure: Check the connection cable, replace the sensor. Until then the channel can follow another one or keep running in manual output mode – the four reactions are explained in Section 6.6, “Temperature monitoring”, they are set under TFL-07, “In case of errors…”.

WRN-08 Heat sink warm

Cause: The temperature at the heat sink of the controller board is too high.
Measure: Ensure better ventilation (free convection), distribute the load better across the tool connectors. What happens above this warning is described in Section 6.8, “Power limits and power reduction”.

WRN-09 Temperature

Cause: The channel had reached its setpoint and afterwards left the warning band. Unlike WRN-04 and WRN-05, this warning therefore reports a deviation during operation and not the heat-up.
Measure: Look for the cause in the process: heat dissipation, change of material, neighbouring zone. See Section 6.6, “Temperature monitoring”.

WRN-10 Phase current

Cause: The channel alone demands more current than the entire budget of its phase provides. It therefore never gets its turn – it stays off even when no other channel on the phase is heating.
Measure: Raise the maximum phase current as far as the supply permits, see Section 9.2.3, “Basic settings” – or bring the heating circuit of this channel down to a smaller connected value. Put high-current zones on different phases; which channel is on which phase is described in Section 5.2, “Channels, phases and connected load”. How the Thermonom distributes the budget, and why this channel comes away empty, is explained in Section 6.8, “Power limits and power reduction”. If the connected load is permanently insufficient, please ask customer service.

WRN-11 Follow error

Cause: The channel is to follow another one, but its data is missing or out of date – for instance because the follow channel is on a coupled device that has dropped out.
Measure: Check the follow channel that has been set (REG-06, “Follow channel”) and, with coupled devices, the connection, see Section 9.2.7, “Coupling”.

WRN-12 Simulation

Cause: The channel is not fed by its own sensors but by a connected process simulation. This is a test and development state: the device controls on readings supplied by a computer. Production never runs in this state.
Measure: No action needed as long as the simulation is intended. If the message appears on a device in production, notify customer service: the device has not been reset. Restarting always ends the simulation.

WRN-97 Cold junction not available

Cause: An external sensor is set as the source of the cold junction temperature but is not being reported. The device continues to calculate with its internal reference.
Measure: Check the sensor and the line in the tool cable, or switch back to the internal cold junction in the device settings, see Section 9.2.9, “Controller #”. While the warning stands, the temperature displayed can be off by the difference between the two references.

WRN-98 Firmware update

Cause: A firmware update is running on a controller board. Its channels do not heat during that time.
Measure: Wait and do not switch the device off while it runs. The warning clears by itself as soon as the board reports again.

WRN-99 No release for main contactor

Cause: The main contactor may not switch on: either the release of the safety circuit is missing, or a shutdown is holding it off.
Measure: Check the safety circuit and the emergency stop, see Section 7.3, “Main contactor ON/OFF”. If a load shedding preceded it, MSG-60, “Main conductor tripped ‹triggering notification›” names the reason.

Faults – have to be acknowledged

These six events look like warnings but behave like errors: they remain until they are acknowledged. Four of them are found by the controller tuning – it is the only procedure that checks a sensor against the heater.

STG-00 Sensor polarity

Cause: The temperature falls while heating – the two sensor wires have been swapped.
Measure: Swap the polarity in the tool connector or reverse it in the channel settings (TFL-02, “Reverse sensor pol.”).

STG-01 Controller tuning failed

Cause: Timeout or insufficient temperature rise.
Measure: Check the thermal coupling between heater and sensor, check the cable connection, check the power rating of the heater. The tuning needs a cold zone, see Section 6.9, “Controller tuning and control parameters”.

STG-02 Sensor position

Cause: The sensor measures but does not react to the power of this channel – it does not sit at this heating zone.
Measure: Check the assignment of the temperature sensors: the positions of the connection cables in the tool connector, see Section 4.4, “Pin assignments”. This finding detects swapped sensor leads in the tool.

STG-03 External heat

Cause: The temperature does not fall after the end of heating – the zone is being heated from outside as well.
Measure: Check the assignment of the temperature sensors, check the thermal coupling at the heating elements, run the tuning for the affected channel individually.

STG-04 Sensor short circuit

Cause: No appreciable temperature rise although a lot of energy has flowed into the channel – the sensor wires touch in front of the measuring point.
Measure: Check the connection cables of the temperature sensor for a short circuit, check the thermal connection between heater and sensor. The detection is switched off ex works, see TFL-10, “Sensor short detection”.

STG-05 No phase

Cause: No phase is present in the device; the main contactor has been dropped.
Measure: Check the supply and the building-side fuse, see Section 5.4, “Connecting power supply”. Then acknowledge on the device.