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10 reasons that will convince you.
MCS - Hot runner controller that meets the highest
demands
Measure
Control
Automate
2
About Feller EngineeringINDUSTRIAL ELECTRONICS FOR MEASUREMENT AND CONTROL TECHNOLOGY
PHILOSOPHY
Founded by Erich Feller in 1972,
Feller Engineering focuses on
the research and development
of industrial electronics.
Quality, flexibility and customer
focus are the cornerstone of our
philosophy. We know how
important it is to our customers
that their requirements are
translated into functional
products.
We develop, manufacture and
distribute all of our products
ourselves.
SERVICES
Feller Engineering develops
electronic modules with a focus
on components for process
automation, such as tempe-
rature controllers and modular
multichannel temperature con-
trollers for hot runner systems,
and measurement data acqui-
sition units. Our modules con-
nect to a variety of bus systems
and also visualise processes.
Our team of experienced pro-
duct development engineers,
technicians and electro-
technicians make us a compe-
tent partner for serial products
and customer-specific solutions.
INDUSTRIES
We serve a variety of industries
ranging from plastics processing
through to machinery and
plants and cleanroom appli-
cations in medical engineering.
Typical areas of application for
temperature control are:
� Hot runners used in injection
moulding
� Automotive adhesive
assembly lines
� Extrusion, blow moulding
and injection moulding
machines
� Packing machines
� Industrial heat tapes
[email protected] +49 6074 8949 - 0www.fellereng.de
3
Meeting the highest demandsCUTTING EDGE TECHNOLOGY � ROBUST � HIGHEST OPERATIONAL SAFETY
MCS hot runner controllers are the result of a
long-standing collaboration with the plastics
processing industry and over 40 years of on-going
experience in temperature controlling
technology.
Our compact controllers combine cutting edge
technology with a high level of functionality. The
controllers’ flexibility and ability to accurately
control temperatures make them suitable for
hot runners of all mmanufactures.
The controllers are extremely robust and easy to
service. Fanless operation for devices starting at
20 zones, fuses that are accessible from the
outside, optimal access to all components for
servicing and the housing’s small footprint make
the controllers unique in the industry.
The control panel and display consist of three
units: a touchscreen for optimal handling and
parameterisation, function keys to quickly select
commands and an additional separate display for
each of the zones that is easy to read from a
distance. This offers the highest level of
operational safety and user friendliness.
Customers can choose from 6 housing sizes,
enabling them to create 2 to 128 control loops
with one device. The controllers can be combined
to expand the number of zones in such a way
that the whole unit works as one controller.
Unique LED strips that are clearly visible from any
angle - even at a distance - indicate the different
operating modes.
Internally, the controllers have a modular
configuration, enabling them to be completely
integrated in the injection molding machine and
thus operated from the machines´s control panel.
MCSr128MCS8 MCS16 MCS32 MCS64 MCSr96
4
PULSED MODE
Output rate = 25%
At a higher output rate, pulsed mode produces the better control behaviour.
The voltage switches at the zero-crossing point, which, among other things,
reduces the wear on the heater.
Innovative control algorithms based on over 40
years of experience in temperature control
technology are the basis of accurate and robust
temperature controls. This means that MCS hot
runner controllers can be used with any hot
runner in the market.
Particularly noteworthy is the special heater
control. Voltage impulses are rapidly emitted (up
to 100 times per second) so that changes to the
control behaviour can be dealt with quickly. This
fast reaction time enables even the smallest of
nozzles to be accurately controlled.
The controllers also have the flexibility to adapt to
highly sensitive processes. Each zone can be
operated separately in pulse mode, with phase-
fired control or in mixed mode. Based on the
output rate, one of the methods will deliver the
better control behaviour. MCS hot runner
controllers switch automatically between both
operating modes.
YOUR BENEFITS
� High control accuracy
� High operating safety
� Robust temperature controller
� Flexible for hot runners of all
manufacturers
PHASE-FIRED CONTROL
Output rate = 10%
At a lower output rate, phase-fired control produces the better control
behaviour. The voltage impulses are small and rapidly emitted in intervals of
10ms.
10ms 10ms
Accurate and robust temperature controller
10 REASONS THAT WILL CONVINCE YOU
1
[email protected] +49 6074 8949 - 0www.fellereng.de
5
Unique operating and display concept
10 REASONS THAT WILL CONVINCE YOU
Red indicates faults or
temperature limits
that have been
exceeded.
The outputs are
deactivated.
MCS hot runner controllers have a
touchscreen for parameterisation
and operation as well as a separate
display for all zones.
This concept is unique and has two
advantages: optimal operation and
parameterisation from the touch-
screen and a very easy to read
display, even from a distance, of a
zone’s current values.
The user can switch between set-
point, actual value, deviations,
output rate and heating current at
the press of a key.
Function keys provide quick access
to special commands without having
to select them on the touchscreen.
A three-sided LED strip indicates the
operating mode and is clearly visible
from a distance.
2
YOUR BENEFITS
� Intuitive touchscreen operation and parameterisation
� Separate, switchable display for all zones
� Optimal visibility of all zone values and operating modes – even from a distance
� Function keys to quickly select commands
Green indicates that
everything is OK. The
controller is operating
normally.
Yellow indicates non-
critical deviations from
normal operation.
Separate display for all zones
LED strip displays the status
Touchscreen
operation
Function keys
6
Maximum power with 16A for all zones
10 REASONS THAT WILL CONVINCE YOU
3
Each of the MCS hot runner controller's outputs
can deliver up to 3,6kW. The outputs for nozzles
and distributors do not have to be specifically
assigned. This makes MCS controllers highly
flexible and usable with different hot runner
systems.
The maximum heating current of 16A is also
guaranteed at higher temperatures inside the
device by the robust wiring and conductor cross
sections. Moreover, only plug contacts are used
that are also designed to handle 16A at high
temperatures.
Individual zones up to 8kW (35A) can also be
equipped with plug connectors.
YOUR BENEFITS
� Highest operating safety even at higher
operating temperatures
� Maximum flexibility in the assignment of
the nozzle and manifold outputs
� Customisations for higher outputs are possible
3,6kW / zone
� 11kW / 16A CEE
� 22kW / 32A CEE
� 43kW / 63A CEE
� 86kW / 125A CEE
Total output Individual output up to 16A
[email protected] +49 6074 8949 - 0www.fellereng.de
7
Comprehensive monitoring functions
10 REASONS THAT WILL CONVINCE YOU
MCS hot runner controllers have extensive
monitoring functions to protect tools, hot runners
and controllers.
All of the functions and parameters that are
relevant to the injection process are constantly
monitored and indicated in the event of a failure.
This includes monitoring the wiring for reversed
polarity, breakages and short circuits. If a sensor
fails, the affected zone can be operated manually
or as the slave of an adjacent zone.
The leakage current monitor has an intelligent dry-
out routine that limits the temperature in the
event of residual moisture or insulation problems,
preventing short circuits.
The output rate monitor detects irregularities in
the heating behaviour, e.g., in the event of a
leaking nozzle. Defective fuses, heaters and triacs
are also detected.
In addition to the monitoring functions that are
active in normal operation, zone or group-depen-
dent diagnostics can also be run. This function is
particularly useful after commissioning or
installation work and it reliably detects incorrectly
assigned heaters and sensors.
Sensor fault/short circuit/reversed polarity
Output rate
Leakage current
Heater
Fuse
Triac
4
YOUR BENEFITS
� High operating safety to protect tools,
hot runners and controllers
COMPREHENSIVE MONITORING FUNCTIONS
8
220
180
-H-
Zone 10
Setpoint [°C]
Actual value [°C]
?
Zone Group All Zones
Troubleshooting for rapid fault location
10 REASONS THAT WILL CONVINCE YOU
MCS hot runner controllers have an integrated
troubleshooter that helps users locate and resolve
faults.
All the user has to do is select the faulty zone on
the touchscreen. The faulty zone is also clearly
visible in each of the zone's separate displays. The
fault code that displays on the screen enables
users to immediately identify the cause of the
problem. A full description of the fault is available
by activating the troubleshooter, which also
provides useful information on resolving the fault.
Downtime is reduced to a minimum.
8
5
YOUR BENEFITS
� Very short downtimes in the event of a
failure
� Clear information on the potential cause
of the fault and its resolution
1. Zone indicator flashes in the event of a
failure
1
2. Activate the fault zone
3
Activate the
troubleshooter
Troubleshooter with
information on locating and resolving faults
4
2
[email protected] +49 6074 8949 - 0www.fellereng.de
9
Mobile control and diagnostics station
10 REASONS THAT WILL CONVINCE YOU
MCScontrol is the optional, user-
friendly touchscreen control and
diagnostic station for the MCS hot
runner controller.
All of the temperatures are
periodically archived on the
integrated hard disk and can be
displayed as a curve chart over a
number of days. This enables users
to analyse and optimise the process.
The process overview displays tools
as a graphic that includes
measurements. The user can control
a zone simply by touching the
corresponding measurement. This
results in a high level of user
friendliness and safety when
defining temperature values.
The Fault Statistics function
automatically focuses on zones with
a high fault frequency. One glance is
all that is needed to check the
continuous process over several
hours and identify the faulty zones.
Temperature curves
6
YOUR BENEFITS
� Graphical display of temperatures over a period of multiple days
(historic trending)
� Intuitive operation with graphical tool display
� Comprehensive tool diagnostics with protocol
� Remote use (up to 100 metres)
� Can be used as a mobile diagnostics station with devices with integrated touchscreen Graphical display of the tool
Diagnostics protocol
The integrated tool diagnostics
check the connected heaters and
sensors. A comprehensive protocol
with information on resolving the
fault is created. Notes can be added
to the protocol and it can even be
printed. The protocol provides a
detailed picture of deviating heating
behaviour and enables decisions to
be made on changing the hot
runner.
MCScontrol
10
Service-friendly Design
10 REASONS THAT WILL CONVINCE YOU
Users can perform the most important service
work on MCS hot runner controllers themselves
such as the replacement of fuses on the output
side. The fuses are at the back of the devices and
accessible from the outside, meaning that the
controllers do not have to be opened and the
fuses can be replaced without requiring any
special technical knowledge.
Users can also replace the triacs in the event that
the outputs' power electronics are damaged by a
short circuit. This prevents expensive repairs and
downtime. Fuses and triacs are delivered standard
with the hot runner controller as part of the spares
package.
Our worldwide agents can help with more
complex service issues. For a current list of our
agents, see www. fellereng.de.
7
External cooling units
Fuses are accessible from the outside of
the device
Exchangeable triacs
Compact power unit with cooling unit and
power electronics
YOUR BENEFITS
� Low downtime
� Low repair costs
� No special knowledge required to replace fuses
� Worldwide support
[email protected] +49 6074 8949 - 0www.fellereng.de
11
Flexible extension of the number of zones
10 REASONS THAT WILL CONVINCE YOU
MCS hot runner controllers enable several
controllers to be combined and operated as one
control unit. This flexibility enables you to expand
the number of control zones in applications where
one controller is not enough without having to
invest in a new and bigger controller.
Data is exchanged between the controllers
through a CAN bus.
The combined controllers work as one controller.
For example, you can operate all of the zones from
the master. Alarms and notifications are also
synchronised. Higher level functions, such as
group heating, are combined across all devices
into one function.
8
Bus connection
MCS16= +
YOUR BENEFITS
� Flexible expansion of the number of
zones with smaller standard devices
� Combined controllers work as one
controller
� Centralised operation
� Continuous number of zones
� Synchronised alarms across all
systems
MCS321 control device with 48 zones
12
Easy machine integration
10 REASONS THAT WILL CONVINCE YOU
The modular design of the MCS hot runner
controller enables all of its components to be
integrated in the injection molding machine. The
controller is operated and visualised from the
machine's control panel.
The controllers are internally divided into modules
such as processors, temperature measurement,
power electronics etc. and are easy to integrate in
standard control cabinets.
Their small footprint provides for a narrower
equipment grid.
The ability to integrate the controllers in machines
is a huge benefit in particular for applications with
high hygiene requirements (e.g., cleanroom
applications in medical engineering). The number
of zones can be expanded at any time by
connecting an external MCS standard controller.
9
YOUR BENEFITS
� Small footprint
� Easy to integrate the hot runner control module in standard control cabinets
� Meets hygiene requirements for
cleanroom applications
� Number of zones can be expanded with
standard controllers
Modular hot runner controller components
integrated in injection molding machine
Hot runner controller can be operated from the
machine´s control panel
[email protected] +49 6074 8949 - 0www.fellereng.de
13
„… We've been working with Feller Engineering
GmbH for over two decades and have come to
know them as an extremely reliable and
competent business partner…“
Satisfied customers
10 REASONS THAT WILL CONVINCE YOU
10
„… The device's service friendliness and the
great support are why we'll continue to use
Feller.“
M+C SCHIFFER GMBH
„… Feller is a great partner, especially when it
comes to finding special solutions for the most
extreme requirements…“
WEIßER + GRIEßHABER GMBHAGRODUR GROSALSKI GMBH & CO. KG
We have been using Feller Engineering's MCS controllers since
we started our own injection moulding factory.
They're extremely reliable and their control quality is excellent,
which is why we have made them our factory standard.
FRESENIUS Medical Care Deutschland GmbH
14
The Auto-Power function enables controlled continued heating in the event
of a sensor failure thereby reducing production downtime.
Several zones can be combined into groups and parameterised as one. This
facilitates commissioning.
GROUPING
The sensor inputs are protected against power surges by a fuse stage. The
pluggable fuses can be quickly and inexpensively replaced in the event of a
failure.
MAINS VOLTAGE PROTECTION FOR SENSOR INPUTS
Cold zones are slowly heated without impacting the slower zones. This
preserves the nozzles and material and prevents a thermal imbalance from
occurring in the hot runner system
GROUP HEATING
Zones can be grouped and sequentially heated up, creating a clean seal on
the nozzle tip. Controlled cooling is also possible.
SEQUENTIAL HEATING AND COOLING
A lot of other functions included
SIMPLY CONVINCING.
CONTROLLED CONTINUED HEATING IN CASE OF A SENSOR FAILURE
Digital control inputs are used to select injection moulding recipes or activate
control commands such as Release and Standby. The alarm contacts enable
centralised monitoring.
CONTROL INPUTS OUT OUTPUTS
The tool storage stores the configuration data for all of the zones. This saves
time and prevents input errors when the machine is restarted after a tool
change.
TOOL STORAGE
All of the zones can be diagnosed to make sure they're working properly. The
detection of inverted or reversed wiring, for example, increases operational
safety.
AVAILABLE DIAGNOSTICS
The Softstart function gently heats up the elements by limiting the power
based on the temperature.
GENTLE HEATING
We deliver the right model for every standard.
CUSTOMER-SPECIFIC PLUG-IN CONNECTORS
[email protected] +49 6074 8949 - 0www.fellereng.de
15
Technical Data
SIMPLY CONVINCING.
OPERATING VOLTAGESwitchable
Tolerance
3x 380-400VAC, N, PE /
3x 220-230VAC, PE
+ / - 10%
POWER CONSUMPTION Idle max. 70W
FUSE OUTPUTS Heat outputs external
Additional fuses internal
each 16A gRL (6,3 x 32mm)
each 16A inert (6,3 x 32mm)
THERMOCOUPLE-INPUTS Fe-CuNi Type J / NiCr-Ni Type K - parameterisable 0..700°C
Reference point compensation internal
Temperature measurement accuracy 0,1K
CONTROLLER-OUTPUTS Bistable, electrical isolated, per zone 1x heating, 230VAC switching
Shortest controller reaction 10ms at 50Hz
Current per zone max. 16A (standard version)
Note: Always observe the total capacity of the mains!
ALARM-OUTPUTS Functions 1x alarm contact and 1x warning contact
RELAY-CONTACTS max. voltage 250VAC
max. current 4A at cosϕ = 1 / 2A at cosϕ = 0,5
CONTROL-BEHAVIOUR PI, PD or PID for all zones separately adjustable Self-adaption of the control parameters
INTERFACE galvanically isolated
RS485, protocol FE3-Bus / Modbus / Euromap / Arburg
CAN-Bus
AMBIENT CONDITIONS Working temperature
range Protection type
0..50°C
IP 20
Housing surface temperature max. 55°C
Storage temperature -25..+75 °C
Humidity < 95% rel. humidity, no drop
WEIGHT / DIMENSIONS WXHXD MCS® 8 / 16 12 / 16kg - 24 / 40 x 21 x 37cm
MCS® 32 25kg - 45 x 28 x 43cm
MCS® 64 / 96 / 128 75 / 90 / 110kg - 50 x 80 / 100 / 120 x 50cm
MCS®rxxx Lower height of 8 cm compared with other standard devices.
Simply convincing
Measure
Control
Automate