MCS-25 (R) - Keys - E-140 - Complete PDF

FELLER ENGINEERING GmbH
MCS®
Operator Manual
For Key-Display
FELLER ENGINEERING GmbH Tel.: +49(6074)8949-0

Carl-Zeiss-Straße 14 Fax: +49(6074)8949-49
63322 Rödermark / Germany Technical-Hotline: +49(6074)8949-31
www.fellereng.de eMail: [email protected]
Version 1.4 Status: 01/15-0513

Operator Manual MCS® For Key-Display
Outputs ON / OFF Home – Zones- Group selection
Boost ON / OFF Parameters (see below)

Change of operation mode
Standby ON / OFF
Control – Manual - OFF
Selection total display Selection total display
 Zone-Parameters (4sec) System-Parameters

 L-Alarm  Slowest Channel
 H-Alarm  Program
 dL/dH-Alarm  Diagnosis program
 xp (P-gap)  Boost-time
 tn (Integral-part)  Friction Control
 tv (Differential part)  Alarm delay
 Classification  Address RS485
 Operation mode  Factor baud-rate „1“
 Monitoring channel  Factor baud rate „2“
 Alternative channel  CAN-Bus-Address
 Softstart  Combined heating
 Combined heating  Auto-Power
 Ramp up  HH-Alarm
 Ramp down  Classification
 Output rate maximun  Leakage current limit
 Output rate nominal  Leakage current supervision
 Output rate mean  Triac supervision
 Output rate mean nominal  Unit of temperature
 Output rate mean tolerance  Brake
 Current nominal  Standard parameters
 Current tolerance  ID Code
 Diagnosis time  ID Level
 Offset temperature  Power-Control
 Zero cross / phase control  Protocol type RS485 „1“
 Boost-Offset  Protocol type RS485 „2“
 Standby temperature  National language
 Auto-Adaption  Thermocouple Type
 No. of group  Cooling Limit
 Leakage current  Voltage line 1…
 Friction Tolerance  Frequency line 1…
Safety hint (see also MCS® - Configuration)

Before connecting to the supply net, the voltage of the 3 lines have to match to the setting of
the controller. MCS® will be delivered for star - or delta-net referring to customer’s demand.
It does not predict of dangerous voltage at the outputs to switch off all out-
puts or single zones!
The referring plugs or the complete MCS® unit have to be disconnected
from the supply net before maintenance of the connected heaters!
Disconnect the MCS® unit from the supply net before open!
Page L-2 Version 1.4

FELLER ENGINEERING GmbH Operator Manual MCS®
Contents
Pages L-
1 Survey of the units 5
1.1 Safety hints 5
1.2 Type label 5
1.3 Features and functions 6
2 Operation 7
2.1 Menu-keys 7
2.2 Indication 7
2.3 LED-stripe 7
2.4 Settings 8
2.5 LED-indicator for the total display 8
2.5.1 Quality of the control 8
2.6 Total display in the front 8
2.7 Outputs ON/OFF 9
2.8 Home-menu - setpoints 9
2.9 Groups 9
2.9.1 Operation of groups 10
2.9.2 Group assembly 10
2.9.3 Sequential heating 10
2.9.4 Sequential cooling off 10
2.10 Operation modes 11
2.10.1 Control mode 11
2.10.2 Manual mode (Power) 11
2.10.3 OFF 12
2.11 Selection of the total display 12
2.12 Boost 12
2.13 Standby 12
2.14 Settings 12
2.15 Indications and request via display 13
2.15.1 Status of the zone 13
2.15.2 Alarms and reasons 14
2.16 Zone-supervision 18
2.16.1 Classification 18
2.16.2 Softstart during heating-up 18
2.16.3 Leakage current supervision 18
2.16.4 Combined heating-up 18
2.16.5 Fuse-supervision 19
2.16.6 Sensor supervision 19
2.16.7 Triac supervision 19
2.16.8 Output rate-supervision 19
2.16.9 Friction Control 19
3 Diagnosis program 20
3.1 Chose the diagnosis program 20
3.2 Selection of zones 20
3.3 Action of the diagnosis program 21
3.4 Stop and skip 21
3.5 End of diagnosis 21
3.6 Failure report of the diagnosis 22
4 PLUS-unit 23
4.1 General settings of the PLUS-unit 23
Status 01/15-0513 Page L-3

4.2 Start of the PLUS-unit 23

4.3 Separation of the PLUS-unit 24
4.4 How to change the PLUS-unit 24
4.5 Hint to the PLUS-unit 24
5 Transport (from MCS®36)
36 25
6 Declaration of EC-Conformity 26
7 Headword-index 27
Technical data and detailed descriptions are to find in the additional

manual
MCS Configuration.
®

1 Survey of the units
The units of the series MCS® are based on two variations. 8-, 16- or 32-zone controllers are
designed for table use, 64-, 96- or 128-zone cabinets are fit with rolls.
MCS®48 (36 – 128) MCS®8 (2 – 32)

Main switch in the front Main switch on the rear side
1.1 Safety hints

The MCS® units have to be connected to the specified supply net. The local and the gen-
eral rules have to be observed for the installation and operation.
The units have to be wired and commissioned by authorised persons.
Maker and vendor of the unit are not liable for direct and indirect damage or loss due to
wrong handling.
It does not predict of dangerous voltage at the outputs
to switch off all outputs or single zones!
The referring plugs or the complete MCS® unit has to be disconnected
1.2 Type label

The type label is to find on the right hand side of the controller. It indicates the type with the
number of zones, the data for the electrical connection and maker’s information.
MCS128 Year: 01/2008

Serial No.: 10 000
Supply Net: [ ] Y 230/400VAC [ ]50Hz
Max. 3x63A [ ] ▲ 220VAC [ ]60Hz
Sensor: Fe-CuNi Protection IP20
Made in Germany CE

1.3 Features and functions

All units include the same functions which are described in the following:
• Total display for all zones
Selectable indication for all zones with single failure messages.
• LED-stripe for permanent signalling
A 270° around LED-stripe indicates 3 status of supervision to see from far away.
• Control loop identification by classification
The controller differences inert from very fast zones by itself.
• Softstart for hot-runners and combined heating
Cold zones will be heated carefully respecting the slowest channel to heat up conformal.
• Boost-function
Increase of temperatures of groups or single zones for settable time.
• Standby-function
Decrease of temperature to a settable value.
• Auto-Power-function
The zone will change to manual mode in case of broken sensor.
• 8 groups of zones
Individual groups may be collected for collective changes and settings.
• 6 Programs with setpoints and zone parameters
A certain profile may be selected even by external digital signal.
• Current measuring and supervision
The heater currents are measured for each zone and may be supervised.
• Leakage current supervision with fast dry-out
In case of leakage current the setpoint of all zones might be reduced to 100°C/212°F.
• Monitor-zones
Individual zones can be used just for indication and supervision.
• Supervision of output rate against entered values.
Prevention against unnoticed alteration by long-time wear out.
• Net-voltage protection for the sensor inputs
High voltage at the sensor inputs will blast the referring fuses.
• Puls-package or phasecut control
The outputs may be controlled in both ways or in a mix of these.
• Sensor control
Each broken sensor or reversal polarity will be detected and indicated.
• Fuse control
Each blasted heater fuse will be detected and indicate by LED.
• Triac supervision
Each defective triac will be detected and indicated by LED.
• Control quality
The control quality may be observed for each zone during the process.
• Interface for computers
Useful for protocols (important for ISO 9000), remote operation and supervision.
• PLUS-unit
Several controllers operate as a single unit via CAN-bus interface.
• Diagnosis
All zones can be checked by an diagnosis program.
• Sequential heating
Selections of zones may be heated in sequences one after another.
• Sequential Cooling
Selections for heating may be cooled down in reverse sequences.
• Friction control
A plugged nozzle may be detected in reason of deviating control behaviour.

2 Operation
The operation display in the top is fit with keys, indicators and LED-stripe.
1 5
2 6
3 7
4
Menu-keys with LED Indicators Settings

2.1 Menu-keys
The menu-keys activate a function or select a menu for operation by the setting-keys. The
referring LED besides the menu-key indicates the selected function.
Key Function Indication

1 ON
Outputs ON/OFF
Flashing, if missing enable or Outputs active/disabled
Alarm confirmation
while cooling down
2 Boost ON/OFF ON Temperature increase
3 Standby ON/OFF ON Temperature decrease
4 Process view ON referring to selection X, W, X-W, Q, I, %
5 Home-menu Return to zone 1
6 Parameters System-, zone-param.
7 Operation mode PID – Hand - AUS
2.2 Indication
The control indication is composed of three indicators:
CHANNEL • the number of the zone (here 128)
  
SETPOINT (W)
• the setpoint of the zone (here 230)
   ☼% with additional LED for manual mode
PROCESS VALUE (X) ☼ °F • the actual value of the zone (here 229)
   with status (failure)
☼ °C with additional LEDs for the selected temperature-
indication
2.3 LED-stripe
A three sided LED-Band signals three possible sates of supervision. The changes happen
synchronous with the dry alarm-contacts (see alarm-contacts). The reaction may be delayed
if required (see AL-parameter). The indications of the zones will never be delayed.
Green = OK / flashes during classification
Green / yellow / red
Yellow = Warning
Red = Alarm

2.4 Settings
CHANNEL The keys beside the zone number select the zone or the
   parameter.
SETPOINT (W) The keys beside the setpoint set the value for the setpoint
   or the parameter.
PROCESS VALUE (X) Each flashing value has to be confirmed by the Enter-key.
Alarm confirmation (chapter 2.15.2)
  
2.5 LED-indicator for the total display

The LEDs indicate the selection for the total display:
Actual value [°C / °F] X % Output rate [%]
Setpoint [°C / °F] W I Current [A]
Deviation [K] ∆T Q Quality [%]
2.5.1 Quality of the control

The selection of the quality in the total display opens the information about the quality of all
control loops. This is more sensible than the deviation ∆T.
The interpretation is calculated by the Root Mean Square of the last 10 seconds in %.
100% correspond with a deviation <0,1K.
Each 1% deviation from 100% corresponds with a deviation of 0,15K / 0,27°F from the
setpoint.
2.6 Total display in the front

The indication in the total display may be selected for all zones. Additional information is
available by the referring LEDs.
Blasted fuse
         
Triac–defect
↑ Cursor ↑ manual mode

The cursor indicate the actually operated zone. These
might be several, when groups are selected.
This indication flashes to indicate selected monitor-zones.
Monitor-zones are not part of groups.

2.7 Outputs ON/OFF

The ON/OFF key enables or disables all outputs. The sta-
2 seconds tus ON will be indicated by the green LED. The outputs
have to be switched ON after each start.
Plug in or out should only happen, when outputs are
disabled!
To enable outputs may be disabled by the digital input
No.5 (see Dip-switch).
Leakage current >300mA inhibit to switch ON!
(see parameter 32)
The turn off may take place delayed in reason of the
sequential cooling off (see sequential heating). Only if
all actual temperatures are below the cool off limit
(COL-Parameter), the outputs will get disabled. By a
further activation of this key the outputs turn off direct-
ly.
Disabled outputs are not without voltage!
Further function Warnings and alarms may get confirmed by this key (chap-
ter Fehler! Verweisquelle konnte nicht gefunden
werden.).
2.8 Home-menu - setpoints

The menu-key returns from any level to zone 1.
CHANNEL The keys beside increase the number of the zone for se-
 lection.
This zone will be indicated in the total display by a LED
like a cursor.
SETPOINT (W) The keys beside the setpoint indicator select a setpoint
   value.
The range is from a disabled zone „- - -“to the HI-value
(see HI-parameter). The upper limit is preset by the HH-
value (see HH-parameter).
2.9 Groups
To operate via groups, these have to be defined before.
It simplifies all further settings and operation to define and configure the groups before. This
enables to separate nozzles from manifolds or different components from another. The real
advantage is the common operation.
All settings are available for groups in the same way as single zones: setpoints, operation
mode, parameters, boost, standby.
The assembly of groups has to be set via zone-parameter 31.
Important hints are to find among Installation of groups.

2.9.1 Operation of groups

CHANNEL The keys beside the zone number select the groups below
   zone 1. Here: group 1
The zones of the group are indicated in the total display by
the LED for the operated zones.
A group may be operated just like a single zone: setpoint,
operation mode, zone-parameters, boost, and standby.
The assembly of the groups has to be set by the zone-
parameter 31.
CHANNEL There is a selection of all zones available below group 8.
   This is independent of the groups.
PROCESS VALUE (X) This indicates that there is no zone belonging to the refer-
ring group or the setpoints, output rates or operation
  modes are different within this group.
In case of different operation modes there are no settings
for parameters available.
PROCESS VALUE (X) The input of setpoints for a group is always relative. I.e.
the input is the deviation of the actual setpoint.
  
Setting: 0...600°C
32..999°F
PROCESS VALUE (X) The input of values for the output rate of a group is al-
ways relative. I.e. the input is the deviation of the actual
   rate.
Setting: -99...100%
The values for the zone-parameters of the groups are to set absolute. The indication is al-
ways “0”, even after the setting.
2.9.2 Group assembly

The assignment of each zone to a group is made by the parameter 31. If the assignment
begins with the greatest group, all zones may be set easily to this group by ALL. Only the
remaining zones have to be changed to the referring groups by parameter 31 one after an-
other.
The contents of a group may be checked by the selection of the group in the total display.
E.g.:
Markings of a group of 12 zones
The total display indicates the selected zones by the referring Cursor-LEDs.
2.9.3 Sequential heating

Parameter 12 enables heating sequences that follow one another. A sequence consists of
one or multiple zones. Before a sequence starts heating the previous one must have reached
a difference of –10K below the setpoints.
The order of the sequences is always started from 8 and finishes at 1. The settings for these
sequences should be entered after the selection of groups, as the selection might be taken
over. (see parameter 12)
2.9.4 Sequential cooling off

The condition to cool off is the setting of parameter 12 for the combined heating resp. the
activation of sequential heating.

The cooling off always starts with the highest assignment. Thus, the last heated zones will
cool off first.
The OFF-key starts the cooling sequence. The referring LED flashes. Analogical with the
heating the zones will only cool off, if the complete previous selection has reached the low
temperature limit (COL-parameter). The LED-stripe flashes yellow until the last zone has
reached this value. All outputs are disabled, when the green ON/OFF-LED dies. By a further
activation of the OFF-key (2 seconds) the sequential cooling off will stop and all the outputs
are disabled directly.
2.10 Operation modes

This key changes the operation mode for the selected
2 seconds zone or group among
Control mode – Manual mode – Off.
Manual mode will be indicated by the LEDs. The indicators
stay dark in the mode OFF.
In case of group-operation the indication of the total display changes to setpoint or output
rate by itself.
Each zone may run reduced operation mode by parameter 9.
• The zone is used for simple temperature indication (monitor), if no outputs are availa-
ble or no heater is connected.
• This is a special mode of a zone without installed inputs or without sensors (manual
Power-mode).
But a connected sensor enables a control-mode, which requires a confirmation of the
output rate after change to manual mode. (see Auto-Power AP).
2.10.1 Control mode

SETPOINT (W) The setpoint will be indicated and may be changed.
   In case of Auto-Power function
the zone changes immediately to manual mode.
In case of group-operation the indication of the total dis-
play changes to setpoint by itself.
This is not possible in manual mode or Auto-Power without sensor.
2.10.2 Manual mode (Power)

SETPOINT (W) P flashes alternating with the actual output rate.
  ☼% The % LED lights.
The LED in the total display indicates the manual mode.
The change to the manual mode proposes the last value
with ☼ LED Manual mode that was used for the manual mode (Parameter 16).
If there is still a sensor connected, the temperature super-
visions L, H, HH as well as the deviations dL und dH are
still active.
In case of group-operation the indication of the total dis-
play changes to output rate by itself.
The system-parameter PC may adjust constant rates to
constant power output within fluctuating net voltage.
This is not possible for Monitor-zones.

2.10.3 OFF
SETPOINT (W) The zone will be turned off without losing the settings.
   If there is still a sensor connected, the temperature and
triac supervisions -H- , HH as well as -S- are still active,
when the setpoints are > 0°.
Total display: ZONE 1 The total display indicates … for the referring zone.
  
2.11 Selection of the total display

This key changes the indicators of the total display. There
are available
Actual values – setpoints – deviations from the setpoint
Output rate[%] – current[A] – control quality
and will be indicated by the referring LED.
The LED for additional information in the total display are
independent of this selection.
2.12 Boost
When outputs are switched ON, the Boost-key increases
2 seconds the temperature of the selected zone or group for a short
time. The status will be indicated by the integrated LED.
all by ☼ Cursor-LED marked The additional setpoint has to be set by zone-parameter
zones 25, the time by the system parameter b-t.
Referring tot he settings this may trigger the dL-warning.
2.13 Standby
When outputs are switched ON, the Standby-key sets all
2 seconds setpoints to a lower setpoint (zone-parameter 26). The
status will be indicated by the integrated LED.
all zones Standby will also be finished by this key.
Referring tot he settings this may trigger the dH-warning.
2.14 Settings
The parameter-key open the entry to all parameters.
Zone-parameters 4 seconds System parameters

2.15 Indications and request via display
2.15.1 Status of the zone

CHANNEL The decimal point in the zone number indicates the coldest
   zone during combined heating stage.
 (see SC-Parameter)
SETPOINT (W) SETPOINT (W) P = manual mode
    alternates
with the output rate (here 27%)
SETPOINT (W) Zone is turned off.

  
SETPOINT (W) P = manual mode
   The output rate has to be set and confirmed.
SETPOINT (W) AC = Alternative Channel with Auto-Power AP = 4

   The number of the zone has to be set and confirmed.
SETPOINT (W) SETPOINT (W) AC = Alternative Channel with Auto-Power AP = 4

     alternates
with the number of the linked zone (here 104).
SETPOINT (W) IC = Identification-Code

   The correct password has to be set and confirmed to un-
lock the settings.
SETPOINT (W) n = Total of zones of a PLUS-unit

   The indicated sum has to be confirmed.
PROCESS VALUE (X) This indication shows, that the controller is Slave 2 (CAN-
address = 3) within a PLUS-unit.
 
(see PLUS-unit)

2.15.2 Alarms and reasons

If the LED-stripe changes to yellow or red, of the referring zone indicates the type of alarm.
The indication for the actual value as well as the total display show the alarm alternating with
the value.
Maintained warnings or alarms may get confirmed. This was specially designed for HH-
alarms and Can-Err to avoid a restart after the failure was solved. Other confirmations are
not possible, as the reasons have to be eliminated.
Conversion °C - °F
red
The time for conversation of all programs and parameters
may amount some minutes during the start after the
    change.
Sensor-failure
red
This sensor has a failure. In case of mixed polarity the
main relay will trip at –15°C/5°F and can only restart after
   OFF/ON.
Temperatures too low, < -15°C/5°F are indicated like dis-

   play overflow.
Reason: • Temperature <-15°C/5°F?

• Polarity +/- of the thermocouple mixed up at the termi-
nal points?
Broken sensor
red
There is no input signal from the sensor.
  
Reason: • Sensor connected?
• Sensor wiring OK?
• Sensor plugs OK?
• Check the NSS-fuses inside the unit
• No Auto-Power function, AP=0
HH-Alarm
red
This actual value is above the HH-parameter. All outputs
get switched off. The controller will go on heating only after
  restart or alarm-confirmation when the actual value has
decreased the HH-parameter.
Not for monitor-zones!
Reason: • Setpoint too close to the HH-value?
• Heating from external?
• Triac defective?
H-Alarm
red
This actual value is above the H-alarm
(parameter 2).All outputs get switched off until the actual
   value decreases below the H-alarm.

Reason: • Alarm limit too close to the setpoint?

• Heating from external?
• Triac defective?
Current-alarm with Triac-LED

red
Current flows without any output rate (0%).
  
With ☼ LED for Triac-failure
Reason: • Triac defective, it is permanent closed!
Depending on the setting of the system parameter SSr the
alarm-contact changes and the main relay turns OFF to-
gether with all heaters. The controller will be ready after
restart and replace of the triac
MCS®2-16 These controllers indicate the concerned zones as well as

all other zones with identical power.
Solving: 1. Take out the fuses of the concerned zones.
2. Turn the controller OFF/ON.
3. Insert the fuses one after another until this indication
appears again. This zone has the defective triac.
Disconnect from the supply net before open!
4. Repeat the sequence in case of several defective tri-
acs.
Current-alarm with fuse-LED

red
No current while output rate >0%.
  
with ☼ LED for fuses
Reason: • Fuse defective?
• Cable or connectors defective?
• Heater defective?
• Triac defective, not closing?
•
Fuse 2-Alarm
rot
(only with option for 2nd internal fuse per zone)
In case of shorted circuit against PE with a blasted fuse
   there may a current heat up the zone. This is only possible
at 3-line power supply without neutral wire. Such current
With flashing ☼ LED for blasted will be detected directly with the turn on and will trip the
fuse main relay.
Ursache: • Extrernal fuse blasted?

• Shorted circuit against PE?
• Cables or connectors defective?
U-Alarm
red
No line-voltage for these zones detected.
See parameter L1-L3, or F1-F3
  
Ursache: • Net supply interrupted?

• Internal upstream fuse blasted?
MCS®2-16: 3 fuses on the controlboard
MCS®20-128: 6 fuses in the terminal bloc
L-Alarm
red
This actual value is below the Lo-alarm.
(see parameter 1)
  
Reason: • Alarm limit too close to the setpoint?
• Heating power sufficient?
• Sensor without contact to this zone?
• Defective output board in the unit?
• Sensor polarity mixed?
LC-Alarm
(red) yellow
The line of this zone has a leakage current, it might dry out
at 100°C.
  The reaction depends on settings the LCL parameter.
MCS®2-16 These controllers will indicate the leakage current of the

concerned zones.
Reason: • The heater must dry out to avoid damages.
• Isolation between heater and PE defective?
d I-Alarm
yellow
The current is out of supervision tolerance.
  
Without LEDs fuse/triac
Reason: • Heater defective or partial failed?
• Nominal current (parameter 20) correct?
• Tolerance (parameter 21) too small?
dY-Alarm
yellow
Deviation of the output rate-supervision is out of tolerance.
 
Reason: • Defective hotrunner system?
• Aging of the heaters?
• Values of output rate (parameter 18) not correct?
• Tolerances too small (parameter 19)?
Negative temperature deviation

yellow
This actual value is below the deviation alarm (parameter
3).
 

Reason: • Heating power sufficient?

• Classification passed?
• Sensor without contact to this zone?
• Defective output board in the unit?
• Deviation alarm (Parameter 3) too small?
Positive temperature deviation

yellow
This actual value is above the deviation alarm (parameter
3).
 
Reason: • Increase deviation alarm (Parameter 3)
• Classification passed?
Total display W-X Difference >- 99K

   The total display cannot indicate this value.
Total display X Actual value < -15°C

   • Temperature too low?
• Polarity mixed, temperature decreases during heating?
Plus-unit without complete connection

red
This indication has to be confirmed at the master of a
PLUS-unit, after it is rebuilt completely.
   There is no power output during this indication.
An alarm-confirmation (see above) is required after solv-
ing.
  
Reason: • CAN-Bus disconnected?
• CAN-Bus missing the termination plug?
• One controller turned OFF?
• Assembly of the PLUS-unit was changed?
Cyclic deviation of friction

gelb
This zone has not reached the minimum deviation of the
value of parameter 33 under activated friction control.
  
Temporary indication!!!
Reason: • There was no friction?
• The requirement (Parameter 33) is too high?
• The supervision time (FrC-Parameter) is too short?

2.16 Zone-supervision
2.16.1 Classification
After switching ON the outputs, the controller runs a classification. The results overwrite the
settings for P, I and D-, even manual settings if the classification differs from the last one.
The procedure will be indicated by the flashing green LED-
green.........green.......
stripe. It may need up to 90seconds for inert big compo-
nents.
The classification may be disabled by the CL-parameter, to save special settings of the P, I
and D parameters.
The range for the start of the classification procedure is 350°C/662°F but at least 30°C/86°F
below the setpoint.
2.16.2 Softstart during heating-up

The advise for hotrunner systems is a slow heating-up at low temperatures with low output
rates. The MCS® controllers are fit with a special softstart routine. This allows a smooth but
efficient heating up. The function can be disabled by zone parameter 11.
2.16.3 Leakage current supervision

SETPOINT (W) The supervision of leakage current registers leakage cur-
  rent from a specified value (LC-parameter). As soon as the
measuring exceeds this value the actual temperature val-
ue alternates with the indication LC.
The indication disappear only 10seconds after falling be-
low the limit.
After plugging or unplugging of heater connectors
LC may appear for a very short moment.
It the setpoints are above 100°C the controller will dry out the hotrunner referring to the set-
ting of the LCL-parameter. The controller will keep the zones at 100°C/212°F until the LC
disappears and the possible humidity has vaporised (see LCL-parameter).
2.16.4 Combined heating-up

The combined heating shall avoid a thermal asymmetric load due to slower and faster zones.
Synchronous heating of all zones takes care of the tool and prevents of mechanical tension
and early worn out.
All zones will be restricted in a certain temperature difference among each other (Ct-
parameter) for synchronous heating. Only the slowest zone will run by maximum rate. The
others will be limited to go ahead with the preset temperature difference. The controller is
looking for the coldest zone during heat up (see SC-parameter).
CHANNEL The SC-parameter indicates „0“if no combined heating is

  active.
During the active stage the number of the slowest channel
SETPOINT (W) / coldest zone will be indicated here.

The combined heating is working even during sequential heating. Fuse supervision
The fuse supervision detects blown fuses. There is no current, when the controller sets the
referring output.
Defective heaters or wiring will result in the same indication.

2.16.5 Fuse-supervision
The fuse supervision indicates blasted fuses, as there is no current when it is required.
Defective heaters or wires may result in the same failure indication.
2.16.6 Sensor supervision

The controller detects missing or broken sensors. The actual value will be set to „-E-” or „-S-
”. This zone may go on by the Auto-Power with restricted function.
Mixed polarity decreases the indication down to „-EE“ and switches the controller off until
restart.
2.16.7 Triac supervision

The triac supervision detects defective triacs, as there is a current, without the controller has
set the referring output.
2.16.8 Output rate-supervision

The supervision of the output rate helps to detect non regular conditions in the heater sys-
tem. After activation the actual mean rate (parameter 17) will be compared to an individual
nominal setting for the output rate (parameter 18). In case of deviations greater than the tol-
erance (parameter 19) the controller will indicate dY for the referring zone.
The setting “0” and the period of heating-up (no mean values available) disable the supervi-
sion.
2.16.9 Friction Control

To determine und supervise the flow through the injection nozzle without any additional in-
stallation, MCS® is able to rate the effect on the temperature increase in reason of the
friction. Friction Control may separate clearly deviating control conditions of a plugged, non-
flowed nozzle from the others.
Therefore the referring zones have to be selected in a common group (parameter 31). The
cyclic supervision starts, if half of the group-selection has a synchronous reaction. Thereafter
all the remaining zones of the group are under surveillance, if a deviation of output rate or
increase of temperature arises. To determine a proper cycle, the zones have to exceed the
required tolerance [%] (parameter 33) and undershoot the period of friction [s] (system pa-
rameter FrC).
The settings need such a dimension, that the resulting indication is sensible enough to state
a deviation. The settings should not be too small, to avoid hyper sensible faulty interpreta-
tion.
Detected zones will be marked by a decimal point in the total display.
If one or more zones of the supervision are not able to
gelb
serve these conditions, a cyclic failure will be indicated
with the yellow LED-stripe and the referring relay contact
   for a period of 2 seconds.
It is important to state, that just the temperature controller has to notice the friction heat to
run the resulting friction control.
The system parameter FrC and the parameter 33 will enable the supervision.

3 Diagnosis program
MCS® is fit with a diagnosis program to check sensors and heaters. This program is espe-
cially to use after first installation or after service.
As described in the following you have to choose the program, select the zones and start.
There are single zones, a group of zones or all zones available for one routine. The stage
runs without operation.
The diagnosis program recovers:
• Mixed sensors or heaters
• Wrong polarisation of sensors
• Shorted sensors.
As this function supervises the intactness of the heaters (a certain increase of temperature is
required during a certain time), it is helpful to use the diagnosis program also, when irregular-
ities occur during normal operation. The period of supervision will be set by the program
itself. It may be preset by the parameter 22 to heat up extreme control loops for 5°.
Selected zones will not be checked,

• if the setpoint = 0,
• if no sensor is recognized –E-,
• if the zone is turned OFF.
During the diagnosis all zones with a sensor, even from the selection excluded zones, will be
supervised by the diagnosis.
3.1 Chose the diagnosis program

ZONE The diagnosis program will be started by the setting of „1“
   in this parameter.
SETPOINT (W)

PROCESS VALUE (X) The confirmation changes directly to the selection of the
zones.

3.2 Selection of zones

ZONE There are single zones, a previously collected group of
   zones or all zones available for this routine.
SETPOINT (W) This alternating indication shows that the diagnosis does
   SETPOINT (W) not run.
PROCESS VALUE (X)

  Start of the diagnosis program.


3.3 Action of the diagnosis program

The diagnosis program runs automatically through the selected zones and may be observed
by the display.
ZONE This section indicates the actually powered zone (here
   ZONE zone No. 24).
SETPOINT (W)
  This section shows the countdown for the actual zone.
  Just this zone has to heat up for 5° during this time.
PROCESS VALUE (X) This section indicates the actual temperature of this zone.
 
Examples from left to right:
1. Zone ready or not checked
2. Zone diagnosis in manual mode
3. Zone not selected
flashing
4. Zone selected, waiting for diagnosis
3.4 Stop and skip

ZONE Besides the indicated zone the up-key may jump to the
  next zone of the selection. Skipped zones are treated like
faultless. This may be used when the diagnosis has to be
repeated.
The repeat of passed zones is only possible by restart of
the routine.
SETPOINT (W) This alternating indication shows that the diagnosis does
   SETPOINT (W) not run.
PROCESS VALUE (X)

  Stop / Start of the referring zone. The countdown restarts
with each start.
 This manipulation may help to increase the temperature
for 5° at inert zones.
3.5 End of diagnosis

ZONE
 
SETPOINT (W) The routine was finished faultless.
  
PROCESS VALUE (X) Finalises the diagnosis program and resets all operation
modes.


3.6 Failure report of the diagnosis

The program stops with the first detected failure.
ZONE
 
Failure report 1
SETPOINT (W) The routine was stopped by a failure.
  SETPOINT (W) The actual zone was not able to heat up sufficiently during
  the countdown.
Reason: • Diagnosis time too short?

• Sensor in wrong position?
• Sensor cable shorted?
Failure report 2
  SETPOINT (W) The output of the actual zone has heated up the sensor of
  this zone.
The cursor-Led of both zones are flashing.
Reason: • Mixed wiring?
• Sensor in wrong position?
• Connectors mixed?
Failure report 3
At the total display
  SETPOINT (W) The output of the actual zone does not lead any current.
 This zone may be skipped by the up-key.
With the fuse-LED
Reason: • No heater connected?
• Fuse blasted?
• Cable defective?
The end of the diagnosis routine has to be confirmed by
2 seconds the On/Off or Enter-key. The operation modes will get re-
set.
Failure report 4
At the total display
The routine was stopped by a failure.
  The temperature decreases while heating (here 13°).
 
Reason: • Sensor polarity mixed?
After solving the failure, the routine should be started again. Zones which are definitely prop-
er, may be skipped.

4 PLUS-unit
A PLUS-unit consists of multiple controllers which may be collected to one unit by a CAN-
Bus interface. The connection happens by the interface cable AU129 with termination
plugs at both ends.
The proper function of the CAN-Bus requires the occupation of both plugs at the rear side of
the controllers. The cable has to be connected directly and the remaining plug must be cov-
ered by a further cable or by the termination plug. This is part of each end of the cable
AU129.
MCS #1 MCS #2 MCS #3

Termination
Termination
AU129 AU129
Termination
Termination
The operation is always enabled by unit #1 = master.

Examples with 3 controllers:
MCS® n1 n2
Zone 10 60 30
CAN-address 1 2..31 3..32
e.g. 1 2 3
e.g. 1 3 5
e.g. 1 10 20
e.g. 1 31 32
The CAN-address 1 activates the master-display operation for all the connected control
zones. All functions are available from here.
The connected controllers “slaves” need a different increased CAN-address from 2 to 32.
The operation is reduced to ON/OFF and the selection of the total display.
Functions as groups, sequential combined heating, warning and alarm, parameters or Auto-
Power are available at a PLUS-unit in the same way as at a single unit.
4.1 General settings of the PLUS-unit

The CAN-address has to be set before the connection with another unit. Therefore the BUS-
cable may be disconnected or the other units have to be turned off.
After setting the CAN-address the controller must get restarted. The available number of
zones flashes and has to be confirmed.
4.2 Start of the PLUS-unit

After all controllers are connected and turned on the total number of zones has to be con-
firmed at the master. The slaves indicate only its number of zones and the slave-No. This
No. results from the hierarchy of the CAN-addresses and fixes the sequence of the slaves.
Example:

ZONE ZONE
     
SETPOINT (W) SETPOINT (W) SETPOINT (W)
  n = ? flashes
     
PROCESS VALUE (X) PROCESS VALUE (X)
  
32 zones Total 164 zones
Slave-No. 1 = CAN-addr. 2 To confirm at the master
4.3 Separation of the PLUS-unit

ZONE After one or more controllers of this PLUS-unit have been
   disconnected or turned off, the system has to be confirmed
at the master, when it is completed.
SETPOINT (W)
  
PROCESS VALUE (X)
For identification of the master Err flashes only there.

  
4.4 How to change the PLUS-unit

A change of the PLUS-unit results from
• Change of the total of zones
• Change of the number of controllers
• Change of the sequence of the slaves
• Any change of address at the slaves.
The following start is equal to the start of a new PLUS-unit.
4.5 Hint to the PLUS-unit

All changes of the constellation of a PLUS-unit will automatically delete the settings for the
Alternative Channel Auto-Power AP=4 to avoid wrong constellations.
The digital inputs are only available via the master for all controllers.
For operation via optional 4“ Touchscreen the parameter No. 28 „Bri“ has tob e set to „1“.
The interface RS485 is no longer available for external devices under these settings.

The handles at each side may be used as shown in the drawing to lift the controller with ap-
propriate ropes.

6 Declaration of EC-Conformity
referring to the following EC standards:

EC-Standard Electromagnetic Tolerance 2004/108/EG
EC-Standard Electrical Appliance 2006/95/EG
Maker:
CARL-ZEISS-STR. 14
63322 RÖDERMARK/GERMANY
TEL.: +49(6074)8949-0
FAX: +49(6074)8949-49
www.fellereng.de
Herewith we declare by signature, that the following described product confirm to the
above mentioned EC standards referring design, production and distribution.
Further applied standards, as far as applicable:

EN 60204 part 1 (Electrical equipment for machinery),
EN 61000-6-1 (EMC immunity), EN 61000-6-3 (EMC radiation)
Product:
Multi-Channel-System temperature controllers MCS® -series
Product name:
MCS®xxx
MCS®control
Year of first CE-sign: 1996
Rödermark, May 23, 2013
Quality supervisor
Registergericht Offenbach HRB 31367, Geschäftsführer: Dieter Skedzun

7 Headword-index
Alarm-confirmation 9, 14, 17
Auto-Power 6, 11, 13, 14, 19, 23, 24
Boost 6, 7, 12
Classification 17, 18
Combined heating 13, 18, 23
Diagnosis 6, 20, 22
Fehlersuche 15
Friction Control 17, 19
Group 9, 10, 11, 12
Leakage current 6, 18
Manual mode 11
Mixed polarity 14, 16, 17
Net-voltage protection 6
Output rate 6, 10, 11, 13, 15, 16, 19
Phasecut control 6
PLUS-unit 6, 13, 17, 23, 24
Sequential cooling off 9, 10
Sequential heating 10, 18, 23
Softstart 6, 18
Trouble-shooting 22
Trouble-shooting 14, 15, 16, 17, 22

Details regarding settings and parameters are to find in the second part
MCS® CONFIGURATION

MCS®
Configuration
Additional Manual
 Zone-Parameters (4sec) System-Parameters
 L-Alarm  Slowest channel
 H-Alarm  Program
 Dev-Alarm  Diagnosis program
 P-Gap  Boost-time
 tn (Integral-part)  Friction Control
 tv (Differential part)  Alarm delay
 Classification  Address RS485
 Operation mode  Factor baud-rate „1“
 Monitoring channel  Factor baud rate „2“
 Alternative channel  CAN-Bus-Address
 Softstart  Combined heating
 Combined heating  Auto-Power
 Ramp up  HH-Alarm
 Ramp down  Classification
 Output rate maximun  Leakage current limit
 Output rate nominal  Leakage current supervision
 Output rate mean  Triac supervision
 Output rate mean nominal  Unit of temperature
 Output rate mean tolerance  Brake
 Current nominal  Standard parameters
 Current tolerance  ID Code
 Diagnosis time  ID Level
 Offset temperature  Power-Control
 Zero cross / phase control  Protocol type RS485 „1“
 Boost-Offset  Protocol type RS485 „2“
 Standby temperature  National language
 Auto-Adaption  Thermocouple Type
 Dead Time  Cooling Limit
 No. of group  Voltage line 1…
 Leakage current  Frequency line 1…
 Friction Tolerance  a.s.o.
Safety hint (see also MCS® - Configuration)

Before connecting to the supply net, the voltage of the 3 lines have to match to the setting of
the controller. MCS® will be delivered for star - or delta-net referring to customer’s demand.
It does not predict of dangerous voltage at the outputs to switch off all out-
puts or single zones!
The referring plugs or the complete MCS® unit have to be disconnected
Version 1.4 Status: 01/15-146

Operator Manual MCS® Configuration
Contents
Pages X-
1 Application 4
2 Parameters 5
2.1 Reset to standard-parameters 5
2.2 Date and time 5
2.3 Select Language 5
2.4 Password – IC 5
2.5 System parameters 5
2.5.1 SC-parameter (Slowest channel) 6
2.5.2 Pro-parameter (Program) 6
2.5.3 Diagnosis program 6
2.5.4 B-t-parameter (Boost-time) 6
2.5.5 FrC- parameter (Friction Control) 7
2.5.6 AL-parameter (Alarm delay) 7
2.5.7 Address-parameter (Address) 7
2.5.8 bAu-parameter (Baud-rate 1) 7
2.5.9 bA2-Parameter (Baud-rate 2) 8
2.5.10 CAn-parameter (CAN-Bus address) 8
2.5.11 Ct-parameter (Combined heating) 8
2.5.12 AP-parameter (Auto-Power) 8
2.5.13 HH-parameter (HH-Alarm) 9
2.5.14 CL-parameter (Classification) 9
2.5.15 LC-parameter (Leakage current limit) 10
2.5.16 LCL-parameter (Leakage current supervision) 10
2.5.17 SSR-parameter 10
2.5.18 FAH-parameter (Fahrenheit-indication) 11
2.5.19 Brake-parameter (Overheat-brake) 11
2.5.20 StP-parameter (Standard parameters) 11
2.5.21 IC-Parameter (ID code) 11
2.5.22 IL-parameter (ID level) 11
2.5.23 PC-parameter (Power control) 12
2.5.24 tP1-parameter (Protocol-type 1) 12
2.5.25 tP2-parameter (Protocol-type 2) 12
2.5.26 LAn-parameter (Language) 12
2.5.27 tEt- parameter (Type of thermocouple) 13
2.5.28 Bri- parameter (Bridge) only for Touchscreen Systems 13
2.5.29 COL- parameter (Cooling off limit) 13
2.5.30 L1-3-parameter (Line-voltage) 13
2.5.31 Fr1-3-parameter (Line-frequency) 13
2.5.32 Date-parameter (Date and Time) 14
2.6 Zone parameters 14
2.6.1 PARAMETER 1: L-Alarm 14
2.6.2 PARAMETER 2: H-Alarm 15
2.6.3 PARAMETER 3: Deviation 15
2.6.4 PARAMETER 4: P-gap for heating 15
2.6.5 PARAMETER 5: I-gap for heating 15
2.6.6 PARAMETER 6: D-gap for heating 15
2.6.7 PARAMETER 7: Classification of the zone 16
2.6.8 PARAMETER 8: Operation mode of the zone 16
2.6.9 PARAMETER 9: Monitoring channel 16
2.6.10 PARAMETER 10: Alternative channel 16
2.6.11 PARAMETER 11: Softstart 17
2.6.12 PARAMETER 12: Combined heating 17
Page x-2 Version 1.4

2.6.13 PARAMETER 13: Ramp up 17

2.6.14 PARAMETER 14: Ramp down 17
2.6.15 PARAMETER 15: Output rate maximum 17
2.6.16 PARAMETER 16: Output rate nominal 18
2.6.17 PARAMETER 17: Output rate mean 18
2.6.18 PARAMETER 18: Output rate mean nominal 18
2.6.19 PARAMETER 19: Output rate mean tolerance 18
2.6.20 PARAMETER 20: Current nominal 18
2.6.21 PARAMETER 21: Current tolerance 19
2.6.22 PARAMETER 22: Diagnosis time 19
2.6.23 PARAMETER 23: Offset Temperature 19
2.6.24 PARAMETER 24: Zero cross / phase control 19
2.6.25 PARAMETER 25: Boost offset 19
2.6.26 PARAMETER 26: Standby temperature 20
2.6.27 PARAMETER 27: Auto-adaption 20
2.6.28 PARAMETER 28: Dead Time 20
2.6.29 PARAMETER 29-30: Reserve 20
2.6.30 PARAMETER 31: Group Number 20
2.6.31 PARAMETER 32: Leakage current 21
2.6.32 PARAMETER 33: Friction tolerance 21
3 Configuration of the unit 22
3.1 Commissioning 22
3.1.1 Dip-switch 22
3.1.2 Jumper 22
3.1.3 Connection 23
3.1.4 Heat-up 23
3.1.5 Finalisation 23
4 Technology 24
4.1 Cable carrier 24
4.2 Document case 24
4.3 Power fuses 24
4.3.1 Internal additional fuses (2nd fuse) 24
4.4 Protection against net-voltage 24
4.5 Rear side 25
4.5.1 Digital inputs 25
4.5.2 Warning- and alarm-contacts 26
4.5.3 Interface socket 27
4.5.4 Signal-light socket 27
4.5.5 Power supply socket 27
4.5.6 Pin assignment 28
4.6 Controllers 28
4.6.1 MCS®20 - 128 28
4.6.2 MCS®2 - 20 28
5 Technical data 29
5.1 Hints to EMC (Electro magnetic compatibility) 30
5.2 Power supply 30
5.2.1 Safety hint 30
36 31
7 Declaration of EC-Conformity 32
8 Headword-index 33
Status 01/15-146 Page X-3

1 Application
This configuration manual bases on the total description of the referring manual MCS® or
MCS®control for the monitor.
All representations for the variations with key-display and the monitor MCS®control are
included.

2 Parameters
The default settings of the parameters are well sufficient for general control requirements.
Customer’s individual setpoints, alarm limits, operation modes a.s.o. have to be set referring
to the task.
2.1 Reset to standard-parameters

ZONE A reset to default settings can be activated by the system
parameter StP.
  
Reloading standard parameters
overwrites all settings by
the default values.
The LED-stripe is flashing during this procedure.
PLUS-units have to be separated for reset.
MCS®control provides a button on the screen „System Parameters“.
2.2 Date and time

See System parameters \ Date-Parameter 2.5.32
MCS®control provides a sub-menu after double click on the digital clock.
2.3 Select Language
MCS®control provides referring buttons on the screen „Settings“.
2.4 Password – IC
The controller is protected against unauthorised settings by the identification code “IC”. The
default code “22” unlocks the settings. This code may be changed from 0…999 by the IC-
parameter.
The code will be retrieved by IC? has to be set and confirmed to unlock.
There are 3 levels to lock the unit. These are available by setting the IL-parameter.
1= total locking: no settings possible without code
2= partial locking: available are ON, setpoints, output rates, boost, standby, change of
operation mode, change of programs and setting for AC?.
3= no locking: all settings are available.
MCS®control opens a menu to enter the password, when required.
2.5 System parameters

These parameters may be used for operation of the MCS® unit. The settings refer to all
zones.
The entry will be opened by the parameter-key.

Pressing the parameter-key for 4seconds opens the entry

>4 seconds to the system parameters.
This passes the zone-parameters.
CHANNEL Further parameters will be reached by the down-key.
 
MCS®control provides a table with system parameters on the screen „Settings“.
2.5.1 SC-parameter (Slowest channel)

CHANNEL This parameter indicates the slowest channel / zone during
  combined heating.
(see Ct-parameter)
Indication: 0...128
Slowest Channel Representation at MCS®control
2.5.2 Pro-parameter (Program)

CHANNEL The Pro-parameter selects one of the 6 programs. Change
   of the program changes the setpoints and zone-
parameters of all zones.
SETPOINT (W) Setpoints and parameters have to be set in the activated
 program and will be stored directly. They are always avail-
able with the referring program.
The program is not enabled as long as the number flashes
ID-Level: 1 in the display.
Input limits: 1... 6
Default value: 1
Program No. Representation at MCS®control
2.5.3 Diagnosis program

ZONE The diagnosis program will be started by the setting of „1“
   in this parameter.
The selection of zone or group will follow before the diag-
nosis starts.
ID-Level: 2 (see diagnosis program)
Input limits: 0...1
Default value: 0
Separate screen Representation at MCS®control
2.5.4 B-t-parameter (Boost-time)

CHANNEL This parameter sets the time for the increase of tempera-
   ture.
The value of temperature has to be set in parameter 25.
The boost mode has to be started by the boost-key.
ID-Level: 2
Input limits: 0...600 s
Default value: 60 s
Boost-Time Representation at MCS®control

2.5.5 FrC- parameter (Friction Control)

ZONE The groupwise friction control will be enabled by a setting
   the period for all zones (parameter 33 >0). This time limits
the supervision within one injection cycle.
• 0s: without supervision
ID-Level: 2 • 1…30s: supervision period for the group
Default value: 0
Friction Control Representation at MCS®control
2.5.6 AL-parameter (Alarm delay)

CHANNEL When an alarm occurs at a zone, the activation of the
  LED-stripe and the relay contacts may be delayed for a
certain time. The setting of „0“activates the alarms imme-
diately without delay. Other values in seconds cause a
ID-Level: 2 delay time.
Default value: 0s
Alarm Delay Representation at MCS®control
2.5.7 Address-parameter (Address)

CHANNEL An interface RS485 is part of the basic equipment of the
   MCS® units. Up to 32 units may be controlled together
via the bus. To communicate with the units it is necessary
to define an address for each unit.
ID-Level: 2 Take care, that two units will never get the same address.
Input limits: 1...32 Otherwise an undisturbed communication will not be pos-
Default value: 1 sible.
A PLUS-unit sets all following addresses by the master.
For operation with the monitor MCS®control the first
address has to be „1“.
RS485 Address Representation at MCS®control
2.5.8 bAu-parameter (Baud-rate 1)

ZONE This parameter sets the baud-rate for transmission via
   rear-side interface RS485-1.
1 = 9.600 baud
2 = 19.200 baud
ID-Level: 2 3 = 38.400 baud
Input limits: 1...5 4 = 57.600 baud
Default value: 2 5 = 115.200 baud
For operation of older MCS® controllers the transmission
has to be set to 1 for 9.600 baud.

2.5.9 bA2-Parameter (Baud-rate 2)

ZONE This parameter sets the baud-rate for transmission via
   processor interface RS485-2.
1 = 9.600 baud
2 = 19.200 baud
ID-Level: 2 3 = 38.400 baud
Input limits: 1...5 4 = 57.600 baud
Default value: 2 5 = 115.200 baud
For operation of older MCS® controllers the transmission
has to be set to 1 for 9.600 baud.
RS485-baudrate Representation at MCS®control
2.5.10 CAn-parameter (CAN-Bus address)

ZONE To enable a CAN-Bus interface for several controllers for a
   PLUS-unit different addresses have to be set here.
• 0: The CAN-interface is disabled to avoid interferences
by open sockets.
ID-Level: 2 • 1: This controller is the master with operation for all
Input limits: 0...32 linked controllers.
Default value: 0 • 2-32: These controllers will be indicated as slave (n) 1-
31 in a PLUS-unit.
See also PLUS-unit.

CAN Address Representation at MCS®control
2.5.11 Ct-parameter (Combined heating)

CHANNEL The maximum temperature difference to the slowest zone
  may be defined here for the combined heating.
The combined heating may be switched off for each zone
separately by parameter 13.
ID-Level: 2
Input limits: 1°C/32°F See combined heating
...100°C/180°F
Default value: 25°C/45°F
Combined Heating CT-Gap Representation at MCS®control
2.5.12 AP-parameter (Auto-Power)

CHANNEL The AP-parameter disposes the selection of output rate,
  when the manual mode is activated by a broken sensor.
• AP=0: output rate = 0%, when the sensor is broken.
The zone remains in control mode and switches the out-
ID-Level: 2 puts off.
Input limits: 0...4 • AP=1: output rate = mean output rate, when the sen-
Default value: 0 sor is broken. This zone changes to manual mode.
The mean output rate (parameter 17) will be indicated.
This proposal has to be confirmed by the Enter-key.
This indication asks for the output rate, if no mean rate
(parameter 17) has been calculated before.
• AP= 2: output rate = mean rate (parameter 17), like
AP=1 without confirmation by the Enter-key.
• AP=3: output rate = preset rate (parameter 16), with-
out confirmation by the Enter-key.

• AP=4: output rate = alternative-%, offers the input of

a similar zone, which will run this zone synchronously.
The flashing indication “AC?” asks for the input of the al-
ternative channel / zone. The input will be stored in
parameter 10 and will be used for the next time without
asking.
It is possible, that several zones are linked to the same
alternative zone.
Auto-Power Representation at MCS®control
For AP = 2, 3 and 4 (when the AC was preset) the zone changes directly to manual mode,
when the sensor is broken. The confirmation by the operator is not required.
When the sensor has been returned, the operation mode has to be changed to the control
mode.
AP = 1, 2 and 3 offer a constant output rate.
ATTENTION
We strictly point out that the temperature is not controlled, when the sensor is broken!
When a constant output rate is set, external conditions may change the actual temperature of
the zone. The manual mode is defined for emergency operation to keep the process tempo-
rary running. The defective sensor should be replaced as soon as possible.
2.5.13 HH-parameter (HH-Alarm)

CHANNEL The HH-parameter (HH-alarm) sets the upper temperature
  limit of the unit. Overriding of this temperature activates
the HH-alarm. HH appears in the display and the main
relay switches off. All outputs will turn off. The controller
ID-Level: 2 may go on heating only after restart when the actual value
Input limits: 1...600°C / has decreased the HH-parameter.
999°F If the HH-parameter should be set below any setpoint, so
Default value: 500°C / will these setpoints increase with the HH-value.
932°F Input limit 800°C/999°F for sensor type „K“ (see tEt)
HH-Temperature Representation at MCS®control
2.5.14 CL-parameter (Classification)

CHANNEL This parameter selects the classification. The classification
  will be passed directly after the start and creates new set-
tings for P, I and D. Even manual settings may get lost
when the conditions have changed meanwhile.
ID-Level: 2 To save special settings, the classification must be
Input limits: 0, 1, (2) switched off = “0”.
Default value: 1 = ON “2” will reset previous results and start a new classification
routine. The setting will directly return to “1”.
Classification Representation at MCS®control

2.5.15 LC-parameter (Leakage current limit)

CHANNEL The limit for indication of leakage current has to be set
  here. It will be measured by the sum per line..
After plugging or unplugging of heater connectors

ID-Level: 2 LC may appear for a very short moment!
Input limits: 10..300mA
Default value: 120mA
MCS®2-16 Provide measuring and supervision per zone.
MCS®20-128 Provide measuring and supervision per line.
LC Limit Representation at MCS®control
2.5.16 LCL-parameter (Leakage current supervision)

CHANNEL The reaction in case of leakage current may be selected
   by this parameter.
• 0 = disabled, no measuring
• 1 = indicates LC by warning
ID-Level: 2 • 2 = indicates LC by alarm
Input limits: 0...6 • 3 = indicates LC by warning and dries all zones at
Default value: 3 100°C/212°F.
• 4 = indicates LC by alarm and dries all zones at
100°C/212°F.
• 5 = indicates LC by warning and dries only this zone at
100°C/212°F.
• 6 = indicates LC by alarm and dries only this zone at
100°C/212°F.
Dry out will only be activated during heat-up below
100°C/212°F.
LC Supervision Representation at MCS®control
2.5.17 SSR-parameter
ZONE This parameter selects the way of triac supervision.
   • 0 = Disabled, no supervision
• 1 = indicates SSr by alarm
• 2 = indicates SSr by alarm and turns the main relay off
ID-Level: 2 All outputs will turn off. The controller may go on heat-
Input limits: 0...2 ing only after restart after the triac was changed.
Default value: 2
TRIAC Supervision Representation at MCS®control

2.5.18 FAH-parameter (Fahrenheit-indication)

CHANNEL This parameter indicates the setting for °F of the unit.
   • 0: °C
• 1: °F
(see DIP-switch)
Indication: 0, 1
PROCESS VALUE (X) ☼ °F An LED beside the actual value (here 229) indicates al-
ways the type of temperature measuring.
   ☼ °C
Unit of Temperature Representation at MCS®control
2.5.19 Brake-parameter (Overheat-brake)

ZONE This parameter sets an additional brake for aggressive
   control loops. In spite of fast answers to disturbances the
brake will prevent overheating during heat up.
• 1 = Disabled, no brake
ID-Level: 2 • 2...20 = Brake factor
Input limits: 1...20
Default value: 2
Brake Representation at MCS®control
2.5.20 StP-parameter (Standard parameters)
CHANNEL A reset of all settings can be started by this parameter.
   • 1 = Reload the standard parameters
StP is only available by the code.
Reloading standard parameters
ID-Level: 4 overwrites all settings by
Input limits: 0, 1 the default values.
Default value: 0 The procedure may need some minutes for all zones, pro-
grams and parameters.
Screen for Settings Representation at MCS®control
PLUS-units have to be separated for reset.
2.5.21 IC-Parameter (ID code)

CHANNEL A new password will be set here. This password has to be
  entered when asked to unlock the unit. After the setting of
a new password, the unit will be unlocked.
A three-digit entry-code (ID-Code) will be set here. This
ID-Level: 4 code unlocks the controller.
Input limits: 0...999 IC is only available by the code.
Default value: 22
2.5.22 IL-parameter (ID level)

CHANNEL The IL-parameter disposes of the level of lock, which inhib-
  its the input of settings.
• 1: Only setpoints and operation mode are unlocked.
• 2: All parameters are locked
ID-Level: 4 • 3: No locking, except level 4
Input limits: 1...3 IL is only available by the code.
Default value: 2

2.5.23 PC-parameter (Power control)

ZONE The PC-parameter activates the reference-voltage for the
   balance of the power in manual mode. Constant output
rates will be adjusted to constant power output in case of
fluctuating net voltage.
ID-Level: 2 • 0: No settings
Input limits: 0, 1 • 1: Detection of the reference-voltage followed by the
Default value: 0 indication of the value.
Indication e.g.: 226 [VAC] A new reference-voltage may be detected by repetition of
the setting „1“.
Power control Representation at MCS®control
2.5.24 tP1-parameter (Protocol-type 1)

ZONE The parameter tP1 defines the type of protocol fort he
   rear-side interface RS485-1.
• 0: FE3 for MCS®control, Visual-Fecon, Para-
con
ID-Level: 4 • 1: Euromap 17
Inputs limits: 0…1
Default value: 0 The reset at MCS®r might be possible only by DIP-
switch 4 (happens at each Start in position ON).
Separate menu: Representation at MCS®control
2.5.25 tP2-parameter (Protocol-type 2)

ZONE The parameter tP2 defines the type of protocol fort he
   processor interface RS485-2.
• 0: FE3 for MCS®control, Visual-Fecon, Para-
con
ID-Level: 4 • 1: Euromap17
Inputs limits: 0…1
Default value: 0 The reset at MCS®r might be possible only by DIP-
switch 4 (happens at each Start in position ON).
Separate menu Representation at MCS®control
2.5.26 LAn-parameter (Language)

ZONE The parameter LAn defines the language, which has to be
   indicated at master controllers with data-wheel in a PLUS-
unit.
• 0: German
ID-Level: 4 • 1: English
Einstellgrenzen: 0...3 • 2: Italian
Standardwert: 0 • 3: Slovakian
Language MCS® Representation at MCS®control

2.5.27 tEt- parameter (Type of thermocouple)

ZONE The tEt parameter sets the type of required thermocouple
   for all zones of the MCS® controller.
• 0: Fe/CuNi type J
• 1: Ni/CrNi type K with temperature range max. 800°C
ID-Level: 2 parameter HH, P1, P2 max. 800°C
Input limits: 0, 1
Default value: 0
Type of Thermocouple J/K Representation at MCS®control
2.5.28 Bri- parameter (Bridge) only for Touchscreen Systems

The Bri parameter defines the master for the operation of
PLUS units. This has to be selected among 4”
Touchscreen at the controller and the external
MCS®control.
ID-Level: 2 • 0: all functions for all poeratin devices, but 4”
Input limits: 0, 1 Touchscreen only for this MCS®
Default value: 0 • 1: PLUS-Unit with 4” Touchscreen at MCS® without
external MCS®control (Lite)
Touch for MCS® PLUS Representation at MCS®control
2.5.29 COL- parameter (Cooling off limit)

ZONE The COL- Parameter enables the sequential cooling and
   sets the lower limit for cooling off. Only after reaching this
temperature the next sequence will start cooling off. When
all zones have reached this level the outputs will get disa-
ID-Level: 2 bled.
Input limits: 0...200°C • 0°C: without sequential cooling
Default value: 0 • 1..200°C: low limit for cooling off
Cooling Off Level Representation at MCS®control
2.5.30 L1-3-parameter (Line-voltage)

ZONE These parameters indicate the actual voltage of the refer-
   ring lines.
• 1: Line 1 for zones 1, 4, 7...
• 2: Line 2 for zones 2, 5, 8...
Only indication [VAC] • 3: Line 3 for zones 3, 5, 9...
Failed line-voltage will indicate -U- for these zones.
L1 Voltage Representation at MCS®control
Not available at MCS®2-16.
2.5.31 Fr1-3-parameter (Line-frequency)

ZONE These parameters indicate the actual net frequency of the
   referring lines.
• 1: Line 1 for zones 1, 4, 7...
• 2: Line 2 for zones 2, 5, 8...
Only indication [Hz (cps)] • 3: Line 3 for zones 3, 5, 9...
Failed frequency will indicate -U- for these zones.
L1 Frequency Representation at MCS®control

2.5.32 Date-parameter (Date and Time)

ZONE The actual date and time may be indicated and set by
   day these 5 parameters.
The settings are only required for additional options.
ZONE
   month
ZONE
   year
ZONE
   hours
Hours will be set in 24h mode.
ZONE
   minutes
2.6 Zone parameters

Each zone has a set of 32 parameters. Selection and setting of parameters as below:
Parameters can be reached by the parameter-key. In the
parameter-level the zone number and the parameter num-
ber are indicated with additional dots.
CHANNEL The keys beside the zone number select the zone or the
   parameter.
SETPOINT (W) The keys beside the setpoint set the value for the parame-
   ter.
PROCESS VALUE (X) The selected number of the parameter (here 2) appears in
the lower display.
  

The touch on the parameter-key or any other on the left
leaves the parameter level.
The functions of the different parameters are explained in the following.
2.6.1 PARAMETER 1: L-Alarm

PROCESS VALUE (X) The referring zone will indicate Lo-alarm, when the tem-
perature falls below the value of parameter 1. This will be
   indicated by flashing „-L-“alternating with the actual value.
ID-Level: 2 At the same time the alarm-contact switches.
Input limits: 0...600°C Input limit 800°C/999°F for sensor type „K“ (see tEt)
32..999°F
Default value: 0°C
L-Alarm Representation at MCS®control

2.6.2 PARAMETER 2: H-Alarm

PROCESS VALUE (X) The referring zone will indicate H-alarm, when the temper-
ature reaches the value of parameter 2. This will be
 
   indicated by „-H-“alternating with the actual value.
ID-Level: 2 The alarm-contact switches and the main relay turns all
Input limits: 1...600°C heaters off. After decrease of the temperature the outputs
32..999°F will be powered again.
Default value: Input limit 800°C/999°F for sensor type „K“ (see tEt)
400°C/752°F
H-Alarm Representation at MCS®control
2.6.3 PARAMETER 3: Deviation

PROCESS VALUE (X) As soon as an actual value will deviate for more than the
value of this parameter, the referring zone will indicate

   deviation. This will be indicated by flashing „dL“ or „dH“
ID-Level: 2 alternating with the actual value. At the same time the
Input limits: 1...600K Warning-contact switches.
Default value: 15K
DEV-Alarm Representation at MCS®control
2.6.4 PARAMETER 4: P-gap for heating

PROCESS VALUE (X) Parameter 4 allows to adjust the proportional gap of the
control loop in percent.
   That means, that a pure P-controller slowly decreases the
ID-Level: 2 output rate proportionally. When the actual value = the
Input limits: 0...100% setpoint the rate will be reduced to 0%.
Default value: 5% for xp =0: P-gap is disabled
Settings of this parameter will be adapted after classifica-
tion.
P-Gap Representation at MCS®control
2.6.5 PARAMETER 5: I-gap for heating

PROCESS VALUE (X) Parameter 5 allows to adjust the integral gap of the con-
troller in seconds. This component of the controller
   increases or decreases the output rate with the defined
ID-Level: 2 speed according to a possible deviation.
Input limits: 0...999s for tn = 0: I-gap is disabled
Default value: 80,0s Settings of this parameter will be adapted after classifica-
tion.
I-Part Representation at MCS®control
2.6.6 PARAMETER 6: D-gap for heating

PROCESS VALUE (X) Parameter 6 allows to adjust the differential gap of the
controller. This component of the controller ‘brakes’ the
  
 output rate for the stored time, if the actual value ap-
ID-Level: 2 proaches the setpoint with too high speed.
Input limits: 0...999s for tv = 0: D-gap is disabled
Default value: 16,0s Settings of this parameter will be adapted after classifica-
tion.
D-Part Representation at MCS®control

2.6.7 PARAMETER 7: Classification of the zone

PROCESS VALUE (X) The type of classification will be indicated by this parame-
ter. Settings are not possible.
  
Indication: 0..9
Classification Representation at MCS®control
2.6.8 PARAMETER 8: Operation mode of the zone

PROCESS VALUE (X) The 3 operation modes are to set by this parameter or by
the referring key in the front.

   0 = OFF
ID-Level: 1 1 = Manual mode
Input limits: 0...2 2 = Control mode
Default value: 0
Operation Mode Representation at MCS®control
2.6.9 PARAMETER 9: Monitoring channel

PROCESS VALUE (X) This parameter enables to select a zone for controller pur-
pose or for simple indication. A Monitor-zone will be
  
 accepted from the group. Monitor-zones can be used for
ID-Level: 2 supervision by the settings of parameters 1-3.
Input limits: 0..2 Deviations are only available when the setpoint >0°C/32°F.
Default value: 0 • 0: controller
• 1: monitor-zones will be used for simple indication,
when no outputs are available or no heater is connect-
ed.
• 2: Manual power mode for this zone, when no inputs
are available at the controller.
However a sensor will enable a control mode without
confirmation after change to manual mod (see Auto-
Power AP).
• The cursor-LED flashes in the total display when a
monitor zone is selected.
Monitoring Channel Representation at MCS®control
2.6.10 PARAMETER 10: Alternative channel

PROCESS VALUE (X) This parameter enables to select an alternative channel for
the Auto-Power mode AP=4.

   The number of the referring zone will be set here after
ID-Level: 2 AC?. It is available for the next case of a broken sensor.
Input limits: 0...128 • 0 or this zone: no preset
Default value: 0 • 1…128: this zone delivers the output rate in case of a
broken sensor.
The input limit for PLUS-units is the total number of zones.
In case of changes of variations of the PLUS- unit, this
parameter will be reset to “0”.
Alternative Channel Representation at MCS®control

2.6.11 PARAMETER 11: Softstart

PROCESS VALUE (X) The unit is provided with a softstart - routine for smooth
heating. This may be enabled or disabled here.
   • 0: this zone without softstart
ID-Level: 2 • 1: this zone with softstart
Input limits: 0...3 A quickstart with occasional overheating is available for
Default value: 1 tasks with very inert control loops
• 2: this zone without softstart, with quickstart
• 3: this zone with softstart and quickstart
Softstart Representation at MCS®control
2.6.12 PARAMETER 12: Combined heating

PROCESS VALUE (X) The unit is provided with a sequential combined heating
function. This zone may be set to a sequence or disabled

   from the combined heating.
ID-Level: 2 • 0: this zone is not combined
Input limits: 0...8 • 1..8: this zone is combined
Default value: 1 The sequences will be heated from 8 to 1 one after anoth-
er. The preferred heated zones have to be set to higher
numbers.
Combined Heating Representation at MCS®control
2.6.13 PARAMETER 13: Ramp up

PROCESS VALUE (X) A consistent slow heating following a ramp, can be acti-
vated here. The function may be reached only, if the
  
 installed heater power is sufficient.
ID-Level: 2 The combined heating is not active in this case.
Input limits: 0...[1°/10s]
Default value: 0
Ramp Up Representation at MCS®control
2.6.14 PARAMETER 14: Ramp down

PROCESS VALUE (X) A consistent slow cooling following a ramp can be activat-
ed here. The function may be reached only, if the installed
   cooling system is sufficient.
ID-Level: 2
Input limits: 0...[1°/10s]
Default value: 0
Ramp Down Representation at MCS®control
2.6.15 PARAMETER 15: Output rate maximum

PROCESS VALUE (X) This parameter limits the maximum output rate of the
heaters.
  
ID-Level: 2
Input limits: 0...100 %
Default value: 100 %
Output Rate Maximum Representation at MCS®control

2.6.16 PARAMETER 16: Output rate nominal

PROCESS VALUE (X) The output rate for Auto-Power function (AP-parameter=3)
must be set here. This parameter does not influence the

   controlled mode.
ID-Level: 2 If this zone has already operated in manual mode, the out-
Input limits: 0...100 % put rate was set here for proposal for the next change to
Default value: 0% manual mode.
Output Rate Nominal Representation at MCS®control
2.6.17 PARAMETER 17: Output rate mean

PROCESS VALUE (X) This parameter will define itself during normal control
mode. It stores the long period average of the output rate
   during the control mode.
The value will be set only 2 min after controlling within the
Indication: 0..100% tolerance range (parameter 3).
0% after start
Output Rate Mean Representation at MCS®control
2.6.18 PARAMETER 18: Output rate mean nominal

PROCESS VALUE (X) This nominal setting will be compared to the actual mean
rate (parameter 17). Deviations will be indicated by dy
  
 • 0: no output rate-supervision
ID-Level: 2 • > 0: this value will get supervised.
Input limits: 0..100%
Default value: 0 (see output rate-supervision)
Output Rate Mean Nom. Representation at MCS®control
2.6.19 PARAMETER 19: Output rate mean tolerance

PROCESS VALUE (X) The tolerance for the output rate deviation (parameter 18)
has to be set here. Within the tolerance range no warning
  
 dY will be indicated.
ID-Level: 2
Input limits: 0..100% (see parameter 18)
Default value: 100
Output Rate Mean Tol. Representation at MCS®control
2.6.20 PARAMETER 20: Current nominal

PROCESS VALUE (X) The nominal value of the current of this heater may be set
here for supervision of the tolerance range of parameter
  
 21.
ID-Level: 2 • 0: no heater current supervision
Input limits: 0,0..25,0A • > 0: this value will get supervised.
Default value: 0,0A
Current Nominal Representation at MCS®control

2.6.21 PARAMETER 21: Current tolerance

PROCESS VALUE (X) The tolerance for supervision of heater current (parameter
20) has to be set here. The current will be supervised by
   the tolerance range of parameter 21.
ID-Level: 2
Input limits: 0,0..16,0A
Default value: 0,5A
Current Tolerance Representation at MCS®control
2.6.22 PARAMETER 22: Diagnosis time

PROCESS VALUE (X) Independent of the internal determined value the duration
of the diagnosis may be set here to the heat up for 5K/
  
 9°F.
ID-Level: 2
Input limits: 0..999s
Default value: 0s
Diagnosis Time Representation at MCS®control
2.6.23 PARAMETER 23: Offset Temperature

PROCESS VALUE (X) This parameter enables to shift the temperature indication
of this zone. The actual temperature and the setpoint will
  
 be calculated with the referring offset against the real tem-
ID-Level: 2 perature.
Input limits: 0
Default value: 0
Offset Temperature Representation at MCS®control
2.6.24 PARAMETER 24: Zero cross / phase control

PROCESS VALUE (X) The output may be controlled by pulspackets or phasecut
or a dynamic mix of both. The selections are:
   • 0: Pulspackets
ID-Level: 2 • 1: Phasecut
Input limits: 0...2 • 2: Mixed
Default value: 0
Zero Cross/Phase-Control Representation at MCS®control
2.6.25 PARAMETER 25: Boost offset

PROCESS VALUE (X) The increase of temperature during the boost-stage has to
be set here by relative values.
  
ID-Level: 2
Input limits: 0...50K
Default value: 0K
Boost Offset Representation at MCS®control

2.6.26 PARAMETER 26: Standby temperature

PROCESS VALUE (X) The decrease temperature for standby has to be set here
by absolute values.

  
ID-Level: 2
Input limits: 0...300°C
32..573°F
Default value: 0°C/32°F
Standby Temperature Representation at MCS®control
2.6.27 PARAMETER 27: Auto-adaption

PROCESS VALUE (X) Für diese Zone kann während der Beheizung eine Anpas-
sung der Regelparameter ausgewählt werden.
   • 0: without parameter adaption
ID-Level: 2 • 1: adaption of P-value during heat up
Input limits: 0...2 • 2: adaption of P, I, D-values during heat up
Default value: 2
Auto-Adaption Representation at MCS®control
2.6.28 PARAMETER 28: Dead Time

PROCESS VALUE (X) Control loops with extreme dead time (delay between
heating impuls and reaction of T/C) may be prepared for
  
 this zone by this setting [per seconds].
ID-Level: 2
Input limits: 0...999s
Default value: 0s
Dead Time Representation at MCS®control
2.6.29 PARAMETER 29-30: Reserve

PROCESS VALUE (X) Without function
  

2.6.30 PARAMETER 31: Group Number

PROCESS VALUE (X) This parameter assembles this zone to a group. The refer-
ring number of the group has to be set here. Groups may
   be set collectively.
ID-Level: 2
Input limits: 0...8 (see groups)
Default value: 0
Group Representation at MCS®control
Group settings will directly overwrite this parameter in the
controller MCS®.

2.6.31 PARAMETER 32: Leakage current

PROCESS VALUE (X) The actual sum of the leakage current of the referring line
will be indicated here.

  
Indication: 0...mA
Leakage Current Representation at MCS®control
2.6.32 PARAMETER 33: Friction tolerance

PROCESS VALUE (X) This parameter enables the friction control. The setting
represents the minimum drop of output rate. The setting

   has to be defined between safe recognition and non-
ID-Level: 2 recognition.
Einstellgrenzen: 0..30 % • 0%: No supervision
Standardwert: 0% • >0%: Minimum drop of output rate
Distance for Friction Representation at MCS®control

3 Configuration of the unit
3.1 Commissioning
The description for commissioning of the unit is anticipated here. If the below listed steps will
be carried out in the described sequence, a failsafe function of the MCS® unit is guaran-
teed. For better understanding of the different functions we recommend to reed this manual.
3.1.1 Dip-switch
There is a 8-fold DIP-switch on the processor module AT202.
Switch Position Function
1 OFF = °C Here the temperature indication may be set from °C to °F. The con-
ON = °F version of all programs and parameters needs some minutes after
restart.
2 The logic of the digital input No. 5 may get inverted here.
OFF • Passive: The outputs of the controller will be disabled by a
24VDC signal.
ON • Activ: The outputs of the controller depend on the enable by
a 24VDC signal.
With disabled outputs the controller cannot get started by the menu-
key. A temporary disable does not generally reset this start.
3 OFF No other position for standard use.
4 Special function to reset the typ of protocol to FE3 at MCS®r with-
out display:
OFF • Default position without function
ON • Reset of parameter tP1 and tP2 to „0“ with the start of the
unit.
Should return to the default position after use.
Operation monitors MCS®control can only be used via FE3-
protocol!
5 OFF Default setting for compact units
ON Setting for MCS®C with external main-relay
The controller has to be turned off before extraction of the module as well as before change.
3.1.2 Jumper
There is a bloc of 2x5 jumpers on the processor module AT202. The default settings are
marked.
Jumper Position Function
1-2 1 = REP NC Warn-contact failsafe, OK = closed
2 = REP NO Warn-contact for lamp/horn, OK = open
3-4 3 = AL NC Alarm-contact failsafe, OK = closed
4 = AL NO Alarm-contact for lamp/horn, OK = open
5-6 5 = Gn-Lo Green LED-stripe damped.
6 = Gn-Hi Green LED-stripe bright.
7-8 7 = Ye-Lo Yellow LED-stripe damped.
9 = Ye-Hi Yellow LED-stripe bright.
9-10 9 = Rd-Lo Red LED-stripe damped.
10 = Rd-Hi Red LED-stripe bright.
The controller has to be turned off before extraction of the module as well as before change.

3.1.3 Connection
• Check the supply net conditions. The terminals inside the controller have to be linked ei-
ther for star/Y-net with neutral (3x400VAC + N + PE) or for Delta-net (3x230VAC + PE).
The referring specification will be delivered with the unit.
• Connection of all heater and sensor cables.
• A signaller may be connected by the alarm/warning-contact of the unit
ATTENTION! Take care of the maximum load of the contacts (see technical data).
• Connection of external digital signals and interface for computer control, if required.
• Connection to the 3phase supply net.
The pin assignment has to be taken from the table inside the controller.
3.1.4 Heat-up
• Turn ON the unit.
• Set setpoints.
• Switch the outputs ON.
• After classification the zones drive to the setpoint temperature. The relevant features like
softstart, combined heating, leakage current supervision and dry out are enabled. These
functions may be disabled.
3.1.5 Finalisation
• Define password and identification level. To inhibit unauthorised operation the password
(IC-parameter) may be changed. For this reason the level of identification (IL-Parameter)
may be changed.

4 Technology
4.1 Cable carrier

At the rear side of the display of units greater than MCS®36 there are 2 cable holders to
pull out. These are provided for the supply cable.
4.2 Document case

On top of units greater than MCS®36 there is a document case below the cover. This may
be used for a notebook. There is a cable entry in the rear wall.
4.3 Power fuses

The fuses for the outputs are to find on both sides of the units. The fuses must comply to the
quality FF. The strength of the fuses may vary referring to the fitting.
The standard is 16AgRL.
4.3.1 Internal additional fuses (2nd fuse)

Controllers, that are powered from a net supply with 3 lines without Neutral, are available
with additional fuses inside the unit. This avoids uncontrolled heating just in case that the 2nd
wire for the heaters are shorted to PE. In case over overload only the external superfast fus-
es will blast.
To change the internal fuses, the controller has to get switched off and disconnected from
the power supply before opening.
4.4 Protection against net-voltage

The units of the MCS®-series are fitted with a fuse module to protect against net-voltage
(NSS-module). These modules protect the sensitive electronics for the sensor-inputs against
unacceptable high voltage. Such voltage may occur by mixed wiring or by defective heaters.
As soon as a voltage higher than 6V is put to the inputs of the NSS-module, the internal fast
fuses will blow. The voltage will be contacted to the ground. The controller will indicate a bro-
ken sensor for this zone.
Replacing the fuses reactivates the referring zone. The fuses are special types which are
plugged at the input module. The user may change these by himself.
The referring zone will be healthy after replacement of the fuses. These are special fuses,
which are plugged on the specially designed NSS-module. The user may replace by his own.
There are spare fuses inside the original MCS® unit.

To change the fuses of the referring module

AT200 the front connectors have to be
plugged out. Then the module may be re-
leased. The cover at the side shows the
position of the different fuses. After lift off the
cover the fuses may get changed.
The cover has to be tightened before replac-
ing the module.
Controllers MCS®2...MCS®16 with maxi-

mum 16 zones are fit with a compact
controlboard. The fuses are to find below a
transparent labelled cover.
4.5 Rear side

At the rear side of the controllers there are the connectors for sensors and heaters, the sup-
ply for an operation monitor MCS®control, the data interface, the digital inputs 2
sockets for an optional signaller (top) and the dry contacts (bottom).
4.5.1 Digital inputs

The unit is fitted with 8 digital inputs. These may be used for remote change of the programs
1...6. A short impulse (min. 100 ms) at the digital input activates the referring program. A
continuous signal at the digital input inhibits the change of programs by the keys or via inter-
face. (For assignment of the 15-pin plug see below)
Via Digit-in Standby the controller may be set to standby mode. This stage will be finished by
a program-signal or the referring key.
Via Digit-in On/Off all outputs are disabled for the duration of the signal. The powered input
*): (see below for the logic of the signals depending on DIP-switch 2 = ON)
• disables all outputs.
• disables the start key for ON.
• erases the LED near the start key.
With the end of the signal the previous status returns.
The inputs are compatible to PLC-voltage of 13..30 VDC at a typical consumption of ca. 8,5
mA.
Digital-In plug
Contact Function
1 Program No.1 Digit-In P1 + 24VDC
3 Disable / Enable outputs *) Digit-In On/Off + 24VDC
4 Standby / no Standby *) Digit-In Standby + 24VDC
5
6-8 0V


13-15 0V
*) may be inverted by DIP-switch 2
Logic of the signals at DIP-switch 2 = OFF

In this position the controller may be used without external enable On/Off.
„ON“
Digit-In On/Off
Digit-In Stdby
Digit-In P1 P1 P1 P1 P1 P1 P1
Digit-In Pn P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
Outputs 0 0 0 1 0 0 1 1 1 1 1 1 1 1 0 0 1 1 1 0 0 0
Standby 0 0 0 0 0 0 0 1 1 0 0 0 1 1 0 0 0 0 0 0 0 0
Logic of the signals at DIP-switch 2 = ON

In this position the remote operation will be failsafe. There is no output without enable by
On/Off. For normal operation without standby there are 2 signals required.
„ON“
Digit-In On/Off
Digit-In Stdby
Digit-In P1 P1 P1 P1 P1 P1 P1
Digit-In Pn P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2 P2
Outputs 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 1 1 1 0 0
Standby 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 1 1 1 0 0
4.5.2 Warning- and alarm-contacts

The MCS® units are fitted with 2 alarm-contacts. The dry contacts for warning and alarm
are available via socket at the rear side.
The function may be inverted (see jumper).
The control voltage 230VAC is also available at this socket for the supply of external signal-
lers. The voltage may be switched by the dry contacts.
Warning-contact
The warning-contact sets a warning, which informs the operator that the process is disturbed.
An immediate action of the operator is not absolutely necessary.
The dry contact is available at pin 1 and pin 3 of the socket at the rear side. The contact is
normally closed (NC).
The contact will be activated together with the yellow LED-stripe with one of the following
warnings:
• broken sensor (only if AP-parameter = 1, 2, 3,4)

• positive temperature deviation
• negative temperature deviation
• current deviation

• leakage current depending on the setting

• deviation of output supervision
• separation of PLUS-units.
Alarm-contact
The alarm-contact sets a main alarm, which requires the action of the operator. This dry con-
tact is available at pin 4 and pin 5 of the socket at the rear side. The contact is normally
closed (NC).
The alarm-contact will be activated together with the red LED-stripe with one of the following
alarms:
• broken sensor (only if AP-parameter = 0)

• shorted sensor
• Triac-supervision alarm
• leakage current alarm
• absolute high temperature (H-alarm)
• absolute low temperature (L-alarm)
• overriding of the HH-parameter (HH-alarm)
• leakage current depending on the setting
• separation of PLUS-units.
Warning- alarm-contact socket

Contact Function Not powered
1.+3. Warning-contact NC
4.+5. Alarm-contact NC
6. Output power 230VAC/4A
7. N Function
see jumper
4.5.3 Interface socket

Contact Function
2 RS 485 B/+
3 RS 485 A/-
Hint of interface address
If several controllers MCS® are connected to a single monitor MCS®control, the ad-
dressing (see Adr-Parameter) has to start by “1” and must be numbered consecutive.
The Baud-rate for the data transmission has to be adapted by the bAu-Parameter, if neces-
sary.
4.5.4 Signal-light socket
Contact Function
1 Warning (yellow) 230VAC
2 Alarm (red) 230VAC
3 N
This socket is designed for an external signal light to be activated together with the functions
of the LED-stripe.
4.5.5 Power supply socket

Contact Function

1 N
2 L
PE PE
This socket is designed for the net supply of a monitor MCS®control.
4.5.6 Pin assignment

The connectors for sensors and heaters are to find at the rear side of the controller. Referring
to the specification the connectors may be wired separated or mixed.
The referring contact list is to find inside of each unit.
This should be kept there for copies, if required.
4.6 Controllers
The controllers inside the units are differently designed. Depending on the number of zones
MCS® operates a system of one single or multiple processors.
4.6.1 MCS®20 - 128
The processor modules are mounted inside the unit onto a rail that includes the interface
connection. The LED in front indicates the status, e.g.
TX flashing – function of the interface
+5V – supply voltage
Input module Processor module Voltage module

with sensor fuses with jumpers and DIP-switches
oat the side
The input modules AT200 have to be set to previous address in case of exchange.
4.6.2 MCS®2 - 20
The compact internal board includes all functions of greater MCS®. The jumpers and DIP-
switches are to find on this board bearing the same functions.
These units may be opened by the cover after loosening the 2 screws below the display
frame.

5 Technical data
Control voltage: 3x190-400VAC, N, PE /

Selectable 3x110-230VAC, PE
Tolerance + / - 10%
Power consumption: Without output max. 70 W
Net-fuses: Control voltage electronics 1 x 0,8A medium inert (5 x 20mm)
Control voltage internal 1 x 4A medium inert (6,3 x 32 mm)
power outputs each 16A gRL (6,3 x 32 mm)
internal additional fuses each 16A inert (6,3 x 32 mm)
Thermocouple-inputs: Fe-CuNi type J 0..700°C/999°F
programmable for Ni-CrNi type K
Temperature deviation by cable- Depending on length and wire di-
resistors ameter
Temperature compensation internal
Accuracy ±0,25 K
Temperature actualisation 4x128 / second
Controller-outputs bistable, electrical isolated
per zone 1x heating, 230V contact
Reaction of controller 10ms at 50Hz
Current per zone max. 16A (standard)
Attention: Take care of the max. load of the supply cables!
Minimum load 100W
Collective alarm out- Functions: 1 x alarm-contact
puts 1 x warning-contact
(Relay-contacts) max. voltage 250V AC
max. current 4A at cosϕ = 1
2A at cosϕ = 0,5
Control routines PI, PD or PID with control-
parameters to set for all zones
separately
Data memory Data storage min. 10 years
(EEPROM)
Serial interface isolated
RS485, Protocol FE3-Bus version 3.03
CAN-Bus
Ambient conditions: Operation temperature 0..50°C/32..122°F
Protection IP 20
Surface temperature of the unit max. 55°C/131°F
Storage temperature -25..+75 °C/-13..167°F
Humidity < 95% rel. humidity,
no dew-drop
Connectors “Han A”: Pollution degree 2 Light pollution
of the contact-inserts
Weight: MCS® 8 / 16 12 / 16 kg
MCS® 32 25 kg
MCS® 64 / 96 / 128 75/ 90 / 110 kg
Dimensions WxHxD: MCS® 8 / 16 24 / 40 x 21 x 37 cm
MCS® 32 45 x 28 x 43 cm
MCS® 64 / 96 / 128 50 x 80 / 100 / 120 x 50 cm
MCS®rxxx Reduced height 8cm
Wiring diagram is enclosed with the unit.

5.1 Hints to EMC (Electro magnetic compatibility)
Interference transmissions:
The unit is relieved according to EN 55011 /B (interference transmissions).
Level of acceptance:
VDE 0839 Part 10
Reliability class Z2
Ambient class S2, I4, E3
Suppression:
VDE 0843 Part l 2,3,4
IEC 801 Part 2,4,5
Ambient class 3
Degree of strength 3, with external filter 4
5.2 Power supply

The MCS® controllers may be supplied by a 220/230V Delta-net, if necessary. For that pur-
pose the links at the terminal strip inside the units have to be moved to another position. The
drawing with the correct positions is to find with the technical documents.
MCS® Standardgeräte sind bezüglich der Netzversorgung umrüstbar. Jedem Regelgerät
wird ein Dokument mit dem Auslieferungszustand mitgeliefert. Dies beschreibt auch die er-
forderliche Umrüstung.
Controllers, that are powered from a, are available with additional fuses inside the unit.
Special MCS® controllers are fit only for the operation at 3x220/230V net supply without
Neutral. These units are to bale to get switched for 3x 400V with Neutral-wire. That is why
neither the referring terminals nor the description belong to these controllers.
5.2.1 Safety hint

The supply from a Delta net without neutral wire „N“has to comply with the local
regulations for the installation of electrical equipment.
MCS® controllers are basically fit with one fuse to protect against short in the
load circuit and against short of one line to PE.
In option, there is an additional fuse per zone inside the unit to protect for Delta
supply even the 2nd line against short to PE. Retrofitting is possible.
The parameters for H and HH alarm limits should be generally adjusted to the
production requirements, to prevent faulty heating.

The handles at each side may be used as shown in the drawing to lift the controller with ap-
propriate ropes.

7 Declaration of EC-Conformity
referring to the following EC standards:

EC-Standard Electromagnetic Tolerance 2004/108/EG
EC-Standard Electrical Appliance 2006/95/EG
Maker:
CARL-ZEISS-STR. 14
63322 RÖDERMARK/GERMANY
TEL.: +49(6074)8949-0
FAX: +49(6074)8949-49
www.fellereng.de
Herewith we declare by signature, that the following described product confirm to the
above mentioned EC standards referring design, production and distribution.
Further applied standards, as far as applicable:

EN 60204 part 1 (Electrical equipment for machinery),
EN 61000-6-1 (EMC immunity), EN 61000-6-3 (EMC radiation)
Product:
Multi-Channel-System temperature controllers MCS® -series
Product name:
MCS®xxx
MCS®control
Year of first CE-sign: 1996
Rödermark, May 23, 2013
Quality supervisor
Registergericht Offenbach HRB 31367, Geschäftsführer: Dieter Skedzun

8 Headword-index
Alarm-contact ............................................................................................................... 22, 27

Auto-Power ............................................................................................................... 8, 16, 18
Boost ...............................................................................................................................6, 19
Classification ..................................................................................................................9, 16
Combined heating ................................................................................................ 6, 8, 17, 23
Commissioning ..................................................................................................................22
Delta-net ........................................................................................................................ 23, 30
Diagnosis ........................................................................................................................6, 19
Friction Control ..............................................................................................................7, 21
Group ............................................................................................................................ 16, 20
Heater current ............................................................................................................... 18, 19
LC Leakage current ...................................................................................................... 10, 21
Manual mode ......................................................................................................................16
Mixed polarity .....................................................................................................................24
Monitor-zone .......................................................................................................................16
Output rate ................................................................................................ 8, 9, 15, 16, 17, 18
Phasecut control ................................................................................................................19
PLUS-unit .................................................................................................................... 7, 8, 16
Program ..........................................................................................................................6, 25
Sequential Cooling .............................................................................................................13
Sequential heating .............................................................................................................17
Softstart ..............................................................................................................................17
Standby ...............................................................................................................................25
Warning-contact ..................................................................................................... 15, 26, 27

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FELLER ENGINEERING GmbH

FELLER ENGINEERING GmbH Tel.: +49(6074)8949-0

Version 1.4 Status: 01/15-0513

Outputs ON / OFF Home – Zones- Group selection

Boost ON / OFF Parameters (see below)

 Zone-Parameters (4sec) System-Parameters

Safety hint (see also MCS® - Configuration)

Page L-2 Version 1.4

Status 01/15-0513 Page L-3

4.2 Start of the PLUS-unit 23

Technical data and detailed descriptions are to find in the additional

Page L-4 Version 1.4

1 Survey of the units

MCS®48 (36 – 128) MCS®8 (2 – 32)

1.1 Safety hints

1.2 Type label

MCS128 Year: 01/2008

Status 01/15-0513 Page L-5

1.3 Features and functions

Page L-6 Version 1.4

Menu-keys with LED Indicators Settings

Key Function Indication

Status 01/15-0513 Page L-7

2.5 LED-indicator for the total display

2.5.1 Quality of the control

2.6 Total display in the front

↑ Cursor ↑ manual mode

Page L-8 Version 1.4

2.7 Outputs ON/OFF

2.8 Home-menu - setpoints

Important hints are to find among Installation of groups.

Status 01/15-0513 Page L-9

2.9.1 Operation of groups

2.9.2 Group assembly

2.9.3 Sequential heating

2.9.4 Sequential cooling off

Page L-10 Version 1.4

2.10 Operation modes

2.10.1 Control mode

2.10.2 Manual mode (Power)

This is not possible for Monitor-zones.

Status 01/15-0513 Page L-11

2.11 Selection of the total display

Page L-12 Version 1.4

2.15 Indications and request via display

2.15.1 Status of the zone

SETPOINT (W) Zone is turned off.

SETPOINT (W) AC = Alternative Channel with Auto-Power AP = 4

SETPOINT (W) SETPOINT (W) AC = Alternative Channel with Auto-Power AP = 4

SETPOINT (W) IC = Identification-Code

SETPOINT (W) n = Total of zones of a PLUS-unit

Status 01/15-0513 Page L-13

2.15.2 Alarms and reasons

Temperatures too low, < -15°C/5°F are indicated like dis-

Reason: • Temperature <-15°C/5°F?

Page L-14 Version 1.4

Reason: • Alarm limit too close to the setpoint?

Current-alarm with Triac-LED

MCS®2-16 These controllers indicate the concerned zones as well as