Synventive eGate Instruction Manual / Installation Manual

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eGate® Hot Runner System

Instruction Manual / Installation Guide

SVC-17-0021_EN-Rev1.0 EN 10 / 2012 RK

Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation

2012-10-12

Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0

Introduction

Dear customers,

We would like to take this opportunity to thank you for your decision to deploy a Synventive eGate® Controller. We are proud to provide you with a high quality standard in pin electronic actuator controller systems. If you have any questions on the applications and the product as such, do not hesitate and contact us by phone or personally.

This manual is designed as a tool for installation, operation and maintenance of your Synventive eGate® Controller and guideline for securing occupational health and safety in connection with the use of this system. You have to carry out any work in compliance with the instructions contained herein. The manual contains essential information, arranged to ensure their general applicability to all Synventive eGate® Controllers.

The employer is exclusively responsible for the protection of workers. The employer therefore has to inform the workers of the safe handling with machinery and its safety-related parts, to train them and to make sure that the machinery is only operated

by trained, qualied personnel.

The employer has to provide the necessary personal protective equipment (PPE), such as protective gloves, hearing protection, protective shields etc. In no case does the documentation provided by Synventive release the employer from its obligations. Synventive does not assume any responsibility for harm done to people in spite of application of the provided documentation.

Synventive’s recommendations regarding the use of certain Synventive products are based on our best knowledge, but do not release you from your obligation to carry out your own calculations and tests to ensure compatibility with the injection mold as well as to determine the product’s compatibility with your technological process.

This manual is intended for toolmakers that deploy controller systems for their electronic actuators in their injection molding processes and for end users, as well as processing plants. If you are a toolmaker, please hand this manual to the end users along with the eGate® Controller.

This document is the property of Synventive Molding Solutions and contains important and condential information.

The document and its parts shall not be in any way copied, sold or disclosed to anyone, as a whole or in parts, without the written consent of Synventive Molding Solutions.

Yours faithfully,

Synventive Molding Solutions

Headquarters:

USA – Peabody, MA

Synventive Molding Solutions 10 Centennial Drive Peabody, MA 01960 Tel.: +1 800 367 5662 Tel.: +1 978 750 8065 Fax: +1 978 646 3600 Email: info@synventive.com

Germany – Bensheim

Synventive Molding Solutions GmbH Heimrodstraße 10 P. O. Box 3123 64625 Bensheim Tel. :+49 (0)6251 9332-0 Fax :+49 (0)6251 9332-90 Email: infohrde@synventive.com

China – Suzhou

Synventive Molding Solutions (Suzhou) Co. Ltd. 12B Gang Tian Industrial Square Suzhou Industrial Park, China 215021 Tel.: +86 512 6283 8870 Fax: +86 512 6283 8890 Email: infohrcn@synventive.com

Customer Service:

North America

24/7 Technical Support Line 1-800-367-5662 – Press 4 from the Main Menu

Europe

Technical Support +49 6251 93320 (8:00 am - 5:00 pm) For after hours service, please contact your local service representative

Asia

24/7 Technical Support +86 512 62831287-666 (8:30 am - 5:00 pm)

+86 13862017765 after hours

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Safety Instructions

1 Safety Instructions

1.1 CE approved Equipment

● Only CE approved equipment rated for application should be used with Synventive Hot Runner Systems.

1.2 Purpose of use of an eGate® Controller System for Hot Runners

1.2.1 Use compatible with the intended Purpose

● The goal of the eGate® Controller System for Hot Runners is to carefully transport the melt with electrically controlled open/close and motion/position prole from the plastication unit to the cavity with an optimum

distribution concept.

● Synventive eGate® Controller System for Hot Runners are not stand alone systems and must be incorporated in the injection mold for use.

● All Synventive eGate® Controller System for Hot Runners are used exclusively for the processing of

thermoplastic materials based on the individual requirements of the specied material.

● A max. injection pressure of 30,000 psi (2068 bar) applies to Synventive Hot Runner standard components (unless otherwise stated).

● Use in conformity with the specied purpose also includes the study and understanding of and the compliance with all instructions and tasks of the submitted instructions for use.

● Synventive eGate® Controller Systems for Hot Runners may be incorporated only into specially designed cavities of injection molds.

● To guarantee a reliable operation of the eGate® Controller System for Hot Runners, it is necessary to comply

with the specied periodic inspections and regular maintenance.

1.2.2 Use in conflict with the intended Purpose

● Synventive eGate® Controller System for Hot Runners may be only used in the manner described in section

1.2.1 Use compatible with the intended Purpose. Any other use is excluded. If the eGate® Controller System for Hot Runners is used in any manner that contradicts the intended purpose, the right to any warranty claims shall cease to exist.

1.3 Definition of Qualified Persons with Technical Knowledge

Technical knowledge means that personnel must -

● Be capable of reading and fully understand injection molding -, hot runner technique and electrical circuits

● Fully understand the interrelationship of the built-in safety systems

● Have knowledge regarding the function and build-up of technical components.

A qualified person is one who, due to his technical training and experience, has sufficient knowledge that he can evaluate the work transferred -

● Can recognise possible hazards.

● Can instigate measures to eliminate hazards.

● has the required repair and assembly knowledge.

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Safety Instructions

1.4 Safety Instructions within the Instruction Manual

● The eGate® Controller System for Hot Runners is an incomplete machine. When the eGate® Controller System is tted into a machine, the interaction between the entire machine and the eGate® Controller System, causes changes to the potential hazards. In particular, the inuence of electrical controls which cause mechanical

movements. This necessitates a hazard analysis and operating instructions for the entire machine.

● These operating instructions are intended to provide information and to prevent hazards when installing the eGate® Controller System for Hot Runners in the machine as well as information and guidelines for transport, storage and maintenance (inspection, servicing, repair) of the eGate® Controller System.

● Only by strictly observing these operating instructions, is it possible to prevent accidents and material damage and ensure fault-free operation of the eGate® Controller System for Hot Runners.

1.5 The eGate® System Instruction Manual / Part of the Synventive Customer Documentation

● Comply with all safety instructions contained in the customer drawings.

● Use customer drawings for general information only. For detailed information, refer to the supplied Synventive

3D model.

Parts of the Synventive customer documentation are:

● User instruction

● Customer drawings

● Electrical wiring information

● Product Certicate / Hot Runner Check List

● Manifold mounting check list

● Parts list

● 3D-Model (in digital form)

● General safety instruction for the Synventive Hot Runner Systems

1.6 Safety Instructions and Symbols used

The following safety instructions and symbols and operating advice are used in this manual. They are highlighted by the respective word. The described measures are used to prevent injuries and avoid damage to the eGate® Controller System and must be followed.

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Safety Instructions

1.6.1 Symbols of Danger Categorisation

Danger

indicates an imminent hazardous situation which may result in death or serious injury.

Warning

indicates a dangerous situation that may lead to irreversible injury.

Caution

indicates a dangerous situation that may lead to reversible injury.

Notice

indicates a situation that may lead to material damage and provides additional information on proper procedures and trouble-free labor without the possibility of personal injury.

1.6.2 Mandatory Safety Signs of the Personal Protective Equipment

Read the user instruction

Wear safety shoes Wear close-tting

working cloth

Wear headgear Wear protective

goggles

Wear face protection

Wear work gloves Wear apron against

high temperature

Wear hearing protection

1.6.3 Warning Symbols

General warning Warning of electrical

danger

Warning of hot surface

Warning of overhead load

Warning of fork lift trucks operating

Warning of falling objects

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Safety Instructions

1.6.4 Product Safety Lable

Electrical danger

1.6.5 Electrical Symbol

Potential earth ground

1.6.6 Components of the eGate® Controller System

● Injection Molding Machine (IMM) is CE approved according 2006/42/EG, 2004/108/EG, 2006/95/EG

● eGate® Hot Runner System is CE approved according 2006/42/EG, 2004/108/EG, 2006/95/EG,

EN ISO 12100 -1:2003/A1:2009, EN ISO 12100-2:2003/A1:2009, EN 60204-1:2006, EN 61000-6-4:2007

● (Pending Safety Approval) eGate® Controller System is CE approved according: EN55022 : 1994 A1 :1995

/ A2 :1998, EN 550011:2007, EN55024.: 1998, EN61000-4-2:1993, EN61000-4-3:1996, EN61000-4-4:1995, EN61000-4-5:1995, EN61000-4-6:1996, EN61000-4-11:1994, EN61000-6-2:2005, ENV50140:1993

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Safety Instructions

1.7 General Safety Instructions

All safety instructions shall be carefully studied before the operation of the Synventive Hot Runner System is initiated. When working with the Hot Runner System, all safety instructions contained here in must be followed.

Noncompliance with safety notes and instructions could result in serious injuries.

Danger to Life by Electric Shock

The electrical cables connected to the eGate® Controller System, Injection Molding Machine and Hot-Runner are under high voltage.

Serious personal injury or death can result from electrical contact.

Electrical work must be carried out by qualied persons.

Verify that all power source connections are properly grounded.

In Emergency case - Switch all systems off.

For first aid contact your medical / safety representing.

Heavy Weight Hazard

Transport and lifting equipment should be operated only by trained personnel.

Use personal protective equipment, such as head gear, safety shoes and work gloves.

Operate lifting and transport equipment slowly and carefully to avoid uncontrolled swinging of the manifold.

Lifting and transport equipment for lifting Hot Runner Systems shall be approved and properly rated taking into account the weight and size of the manifold.

For first aid contact your medical / safety representing.

Hot Surfaces Hazard

Contact between the skin and the hot injection mold could result in burns.

Use personal protective equipment, such as work gloves, apron, sleeves and face protection, to guard against burns.

When servicing or handling the hot runner system outside the manifold plates or the injection molding machine, care must be taken to heed the hot surface exposure warnings.

For first aid contact your medical / safety representing.

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Safety Instructions

Danger of Material Defects

Only approved and CE certied temperature controllers rated for application with

over current / voltage protection should be used with Hot Runner Systems.

Verify that all cables are damage free and in good condition.

Verify that all electrical connectors are clean and making good contact, and are securely fastened and latched. Dirty or otherwise contaminated connector pins can cause loss of signal and subsequent errors.

Clean all connectors with a spray-type commercial electrical contact cleaner / degreaser and allow them to dry fully before reconnecting.

All Synventive Hot Runner Systems shall be tted with a temperature controller

to provide separate temperature adjustment for each heating zone; the controller shall have the Soft-Start function for gradual heat-up. In this way you can prevent premature wearing and damage to the hot runner system.

To extend the lifetime of temperature sensors, avoid long-term operation of temperature control in manual mode.

Immediately replace defective temperature sensors.

If you replace heaters or their parts, always use original spare parts from Synventive and carry out the replacement as described in this manual.

Do not interchange power supply cables with temperature sensor cables. Temperature sensor cables are not suitable for high voltage applications and will melt if exposed to high currents. Power supply cables are not suitable for use as temperature sensor cables for data transfer to the temperature controller.

To maximize the life of temperature sensors, maintain the operating temperature

as specied in the respective material safety data sheets during processing.

Take notice of the production and color identication of temperature sensor cables.

Always use the specied temperature sensor.

Check that the aluminum surfaces of heaters do not come in contact to the nozzle cut-outs. If they do, enlarge the nozzle cut-outs as needed. Any contact between the heaters and the nozzle cut-outs will lead to the risk of improper temperature control, which could result in damage to the aluminum casting.

If applicable, set the necessary operating temperature to the lowest level possible to avoid plastic degradation and to prevent damage to the temperature sensors.

The cooling compound for nozzles with a cooling insert should always have the correct mixing ratio to prevent corrosion and obstructed circulation.

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Service and Maintenance / Pre-Installation

2 Pre-Installation

2.1 Injection Molding Machine Interface

2.1.1 General Safety Instructions for the eGate® Controller

Installation and Wiring Instructions

Read all safety instructions.

● Failure to comply with the instructions may cause serious injury.

● All safety instructions shall be carefully studied before the operation of the Synventive eGate® Controller system

is launched. The eGate® contains static sensitive components that can be damaged by incorrect handling. It is expected these products will be protected from hazardous or conductive materials and/or environments that could cause harm to the unit by damaging components or causing electrical shorts. It is important to protect these items from excessive or corrosive moisture, abnormal ambient temperatures, and conductive materials.

Danger to Life by Electric Shock

The electrical cables connected to the eGate® Controller System, Injection Molding Machine and Hot-Runner are under high voltage.

Serious personal injury or death can result from electrical contact.

Electrical work must be carried out by qualied persons.

Verify that all power source connections are properly grounded.

In Emergency case - Switch all systems off.

For first aid contact your medical / safety representing.

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Service and Maintenance / Pre-Installation

Mandatory

Safety

instructions

Danger of Personal Injury

When unpacking the eGate® Controller system, there is a risk of injury due to falling parts and sharp edges. Handle equipment with care.

Transport and lifting equipment should be operated only by trained personnel.

Only approved and CE certied temperature controllers rated for application with

over current / voltage protection should be used with Synventive eGate® Hot Runner Systems.

Only trained personnel shall have access in danger zones and access to electrical enclosure.

When replacing fuses of the eGate® Controller, switch power to the system to the “Off” position via the rear Power Switch.

Before connecting or disconnecting any cables switch “Off” the rear Power switch to the unit; Cables in the eGate® system and the injection mold interfaces may still be energized.

Failure to do so may lead to damage of the eGate® system or injury to personnel.

Electrical terminals for attaching cables in the eGate® system shall never come

into contact with the coolant or hydraulic uid.

They could be short-circuited or a fire could occur, leading also to damage of the eGate® system or injury to personnel.

Electrical terminals for attaching cables in the eGate® system shall never come

into contact with the coolant or hydraulic uid.

They could be short-circuited or a fire could occur, leading also to damage of the eGate® system or injury to personnel.

End-User System must provide both an “E-Stop” and a Safety Gates Opened interlock to disable the interface between the eGate® Controller and the Injection Molding Machine.

The electrical power cord must be detached from the eGate® Controller unit and in “line of sight” of the service personnel whenever the top panel cover has been removed.

An appropriate CE rated and approved power cord for the native country must be attached to the Synventive eGate® for proper operation and safety.

Failure to do so may cause damage to the controller unit or may be harmful to personnel.

When more than two eGate®Controller’s are stacked, Synventive recommends utilizing a 19”-2U open-rack frame and the side fans must not be blocked.

Blockage of the fans may lead to damage of the eGate® system, fire or injury to personnel.

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Service and Maintenance / Pre-Installation

Mandatory

Safety

instructions

Danger of Material Defects

Only approved and CE certied temperature controllers rated for application with

over current / voltage protection should be used with eGate® HR Systems.

When replacing fuses of the eGate® Controller, switch power to the system to the “Off” position via the rear Power Switch.

Before connecting or disconnecting any cables switch “Off” the rear Power switch to the unit; Cables in the eGate® system and the injection mold interfaces may still be energized.

Failure to do so may lead to damage of the eGate® system.

Electrical terminals for attaching cables in the eGate® system shall never come

into contact with the coolant or hydraulic uid.

They could be short-circuited or a fire could occur, leading also to damage of the eGate® system.

An appropriate CE rated and approved power cord for the native country must be attached to the Synventive eGate® for proper operation and safety.

Failure to do so may cause damage to the controller unit.

“E-Stop” signal immediately disable electrical power to the electronic pin actuators; these conditions prevent their further movement and control by the eGate® Controller.

When more than two eGate®Controller’s are stacked, Synventive recommends utilizing a 19”-2U open-rack frame and the side fans must not be blocked.

Blockage of the fans may lead to damage of the eGate® system.

Please note that each controller requires at least 6.5 A AC. Care must be taken when connecting stacked eGate® controllers to one power outlet or surge protector. Please make sure your power circuit can handle or provide the necessary load requirements for stacked eGate® controllers!

A mains line power switch is located in the rear of the unit which allows 120 Vac and 240 VAC to deliver the required power to the internal AC-DC supplies. The eGate® main power switch will not enable the unit unless the rear switch is “On”.

The I/O button must be pressed and held in conjunction with any other button in order for the pendant to be functional and control electronic actuator motion.

Do not connect power to the eGate® Controller until the system is fully assembled and all cables properly connected as described in this manual.

In harsh environments or when placed near molding machines where plastic particles or other debris are ejected into the air, the eGate® Controller must be

placed in a well ventilated and ltered area insuring does not exceed maximum

operating temperature as described in the hardware Description Section.

Failure to comply may clog up the intake fans and cause the unit to exceed rated thermal requirements and the controller power supplies may shut down or possible damage to the controller may result.

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Service and Maintenance / Pre-Installation

2.1.2 Grounding check

1) Check if the eGate®Controller is grounded, hold a multi-meter between the eGate® Chassis and manifold grounding.

NOTICE

The measured resistance value should be zero Ω.

2.1.3 Warranty Disclaimer

NOTICE

Failure to adhere to all instructions and procedures in the eGate® user’s pre-installation reference may cause damage to equipment or injury to personnel.

Synventive Reserves the right to void equipment warranty!

2.1.4 eGate® Controller Interface Required Parts

For the eGate® Controller system to run correctly and safely with an Injection Molding Machine (IMM), status and control signals are needed for both systems to communicate. This document describes what is needed and the wiring instruction to connect the eGate® controller to the Injection Molding Machine.

Before you start this procedure make sure that you have received the eGate® Controller Interface Kit (part number ELAIMMCK03) which contains the following parts:

eGate® Face Plate Connector

The face plate connector is to be installed on the front side of the injection molding machine.

The face plate is supplied as part of the eGate® Controller Interface Kit (part number ELAIMMCK03)

Doc004406.png

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Service and Maintenance / Pre-Installation

Standard L-com Cable

The standard L-com cable with a D-sub connector and exposed wires on the other end is used to connect the face place to the relays inside the injection molding machine.

The standard L-com cable is supplied as part of the eGate® Controller Interface Kit (part number ELAIMMCK03).

Doc004407.png

Dry Contact Relays (Not Supplied by Synventive)

You need to supply up to 10 dry contact relays. Relays chosen must be CE certified and rated at 24 V with at least a minimum contact rating of 500 mA.

The total coil current requirements of all components used shall not exceed 750 mA. Failure to do so will result in malfunctioning of the IMM interface.

Doc004408.png

Interface Tester and eGate® Interface Cable

Once the interface is wired it should be fully tested using the tester supplied by Synventive (part number ELAIMMTB01). You will also need the eGate interface cable (ELAIMMC4572-02 or ELAIMMC7620-02).

Doc004409.png

Fuse (Not Supplied by Synventive)

Make sure to have a .75 A fuse available.

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Service and Maintenance / Pre-Installation

2.2 eGate® Controller Interface Installation and Wiring Procedure

The procedure to install the eGate interface consists of the 4 steps:

Step

1) Install the face plate connector.

Step

2) Determine which signal will be used from the Injection Molding Machine and where in the IMM can you get the required signals.

NOTICE

These signals will be wired to the provided Lcom cable via the dry contact relays.

Step

3) Wire all signals, grounds and power as described in the wiring instructions.

Step

4) Test the interface signals before attempting to run the eGate® controller.

2.2.1 Step 1) Install the eGate® Face Plate Connector

1) Determine the best place to drill the slot shown on the right. Make sure to select a place that is close to where the eGate® controller will be placed.

NOTICE

The cable length from the interface to the eGate® controller is 7 meters.

2) Cut the slot as shown and properly secure the face plate connector.

Doc004410.png

2.2.2 Step 2) Identify Required and Optional Signals

The eGate® controller requires various signals from the injection molding machine to be wired to the face plate connector. The table below shows the descriptions of the required signals. Without these signals the eGate controller will not work. It is very important that you identify where to tap into these signals on the injection molding machine control panel. Once these tap locations are identified you can proceed with the wiring.

NOTICE

The Recommended Signal – Temperature Setpoint when used can prevent the pins from moving on cold material.

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Service and Maintenance / Pre-Installation

Signal Name Signal

Number / Relay Number

Description Recommended Signal

Application Specic

Required Signal

Mold Clamped

This signal should go high as soon as the Mold is clamped and should go low when the Mold opens. This is a recuired signal as it will give more time for the pins to move out of the gate in critical applications.



Screw forward 1

This signal should go high at the beginning of the injection cycle (as the screw moves forwards) and remain high until the “Pack and Hold” cycle ends or times out. This signal should only be “Active” during “Semi-Auto, and Automatic” press operational mode; Not in manual mode.



Safety gates

This signal must be set high when any of the safety gates of the press are closed. When any of the safety gates are opened, this signal should be low.



HR-Temp SetPoint

This signal must be high when the Mold is at the correct operating temperature. This signal is normally supplied from the temperature controller.



Estop

This signal must be high when there are no emergency conditions created by the E-STOP push button on the press. When there is an emergency condition this signal must be dropped in order for eGate® to disabled all power to the drives.



Screw forward 2

Used only for 2 shot type applications. Must go high when the second shot starts and remain high throughout the second shot.



Screw forward 3

Used only for 3 shot type applications. Must go high when the third shot starts and remain high throughout the third shot.



System restart

This signal must be high once the motor start on the press has been activated after an Estop or Startup condition.



eGate® Error Alarm

The eGate® controller will set this signal high when it encounters any error. This signal can be used to light a light tower, horn or other.



Injection inhibit

The eGate® controller will set this signal low when it is not ready for an injection cycle because an error condition or because the operator has the pendant in manual mode. This signal should be used to prevent the press from injecting.



Table 1 eGate® Interface Signals

2.2.3 Step 3) Wiring Instructions

The recommended wire size is 26 AWG for all of the signals and 24 AWG for ground and power signals.

The total Coil Current requirements of all components used shall not exceed 750 mA. Failure to do so will result in malfunctioning of the IMM Interface.

You should make sure to plan where you will place all of the dry contacts relays. These relays should be dim rail mounted together and near the eGate® face plate connector if possible.

The dry contacts relays for all of the signals are to be wired as shown on Figure Doc004411/12.png dry contact relay wiring for IMM Signals (1->8) below.

The dry contacts for the eGate signals to the press – Error and Injection Inhibit – are to be wired as shown on Figure Doc004413/14.png dry contact relay wiring for error and injection inhibit (9 and 10) below.

The L-com cable provided with the interface kit will be used to connect to the relays, ground and power on the IMM. Follow the schematics and color codes as shown Figure Doc004415.png required signals wiring schematics and wire color codes bellow. (Note: Detailed schematics are also presented in Appendix 1 detailed wiring interface schematics Doc004417.png)

NOTICE

It is recommended that a .75 A fuse is used between the press +24 volts and eGate® pin (14) - purple and white wire.

Once you have completed the wiring of all signals, grounds and power, you can test the interface as described in section 2.3.

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Service and Maintenance / Pre-Installation

2.2.3.1 Dry Contact Relay Wiring for Press Signals (1->8)

Signal from press

Signal to eGate® interface Ground from press

I Signal to press

Doc004411.png

Signal to eGate® interface Signal from IMM

24 V from eGate® Ground from IMM

Doc004412.png

2.2.3.2 Dry Contact Relay Wiring for Error and Injection Inhibit (9 and 10)

Signal from eGate® interface

Ground from eGate® interface Signal to IMM

Signal from IMM

Doc004413.png

Signal from eGate® interface Signal to IMM

Ground from eGate® interface Signal from IMM

Doc004414.png

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Service and Maintenance / Pre-Installation

2.2.3.3 Required Signals Wiring Schematics and Wire Color Codes

N/O

Relay 1

(1) Brown

Wiring from eGate® Interface

Mold Clamped

Screw Forward 1

Signals from IMM

(2) Red

(3) Orange

(4) Yellow

(5) Green

(6) Blue

(7) Violet

(23) Light-Green & Black

(18) Orange & White

(16) Black & White

Safety Gates

HR-Temp SetPoint

E-Stop

Screw Forward 2

Screw Forward 3

System Restart

eGate Error Alarm

Injection Inhibit

IMM +24V

Screw Position 1

Screw Position 2

Screw Position Common

Earth Ground (IMM Chassis)

(19) Green & White

(15) Brown & White

(14) Purple & White

(13) Blue & White

(24) Red & Black

(25) Orange & Black

(26) Yellow & Black

(12) Gray & Black

(11) Black

(22) Gray & Violet

(8) Gray

Drain Wire

(10) Light-Green

(21) Gray & Red

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

N/O

Relay

24V 500mA

.75A Fuse

IMM Ground

0Vdc

N/O = Normally Opened

Release 1.0

Doc004415.ai

Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation

2012-10-12

Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0

Service and Maintenance / Pre-Installation

2.3 Testing the Interface

To test the wiring is correct and all of the signals are working the eGate® Interface Tester which can be requested from Synventive (part number ELAIMMTB01). The Interface Tester allows full check of the interface prior of the installation of the eGate system.

1) Connect the tester to the eGate® front using the eGate® to IMM interface cable (ELAIMMC4572-02 or ELAIMMC7620-02).

2) Set the eGate® front plate interface switch to the UP position.

NOTICE

The green LED should be on.

3) Set the Mode switch on the tester to the UP position.

NOTICE

The IMM LED should turn ON.

4) Make sure that the LED test switch on the testes is DOWN.

NOTICE

Once all switches are set correctly the LEDs on the left side of the tester indicate that the corresponding interface signal is either

ON – LED is ON

or OFF – LED is OFF.

5) For each signal implement, activate it on the IMM and make sure that the corresponding LED on the tester will turn ON.

Emergency Stop

IMM Re-start

Analog Screw Position 1 Input

Safety Gates

Mold Closed

Analog Screw Position 1 Input

Temperature Setpoint

Screw Forward 1

LED Test (switch up)

Screw Forward 2

Screw Forward 3 Mode Switch

UP: To verify IMM wiring

DOWN: To test eGate controller

eGate Error eGate Ready

Switches are used to generate the eGate Error and eGate Ready signals when verifying the IMM wiring

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6) To test the injection inhibit signal from eGate®, turn the eGate® ready Inj Inhibit switch to the up position (green LED will be ON).

7) On the IMM try and initiate a dry cycle.

NOTICE

The IMM should detect the injection inhibit and prevent injection forward.

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Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation

2012-10-12

Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0

Service and Maintenance / Pre-Installation

2.4 Appendix 1 Detailed Wiring Interface Schematics

1 2

Mold Clamped

1 2

Screw Forward 1

1 2

Safety Gates

1 2

1 Mold Clamped

HD-DB26 Male

eGate Interface Connector

(Brown)

E-Stop5

(Green)

Screw Forward 1

Safety Gates

(Red)

(Orange)

HR-Temp SetPoint

6 Screw Forward 2

(Blue)

78Screw Forward 3

(Violet)

(Gray)

Chassis Ground

9 Reserved Ground

(Light-Green)

eGate Ground

(Red / Black)

eGate Ground (Restart)

(Orange / Black)

eGate Ground

(Brown / White)

eGate Ground

(Yellow / Black)

IMM Present

(Gray / Violet)

IMM Ground

(Light-Green / Black)

Motor Restart

(Black / White)

eGate System Alarm

(Green / White)

eGate Not Ready

(Orange / White)

Sys Alarm Rly Com

(Black)

Screw Position 1

(Gray / Black)

Screw Position 2

(Gray / Red)

Injection Inhibit Rly

(Blue / White)

Screw Position Ana Com

(Purple / White)

Press +24 VDC

(Yellow)

HR-Temp SetPoint

1 2

E-Stop

1 2

Screw Forward 2

1 2

Screw Forward 3

1 2

System Restart

eGate Error Alarm

.75 A Fuse

Injection Inhibit

IMM Ground

IMM +24 VDC

IMM Ground

IMM +24 VDC

K10

RELAYS K3 and K5 - must be installed for safety. PIN 8 (Gray) and the drain wire of the interface connector must be wired to earth ground !

SCREW POSITION ANALOG SENSORS (0. .10V)

Screw Position 1 Screw Position 1

Screw Pos Ana Com

Doc004417.ai

Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation

2012-10-12

Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0

Service and Maintenance / Pre-Installation

2.5 Appendix 2 Screw Position Sensor Interface

The screw position sensors are analog transducers and must provide analog output signal voltages from 0 -10 VDC.

The sensors should have an accuracy of about +/- 0.28 to +/- 0.15% FS.

The eGate® Controller’s analog inputs are high impedance > 100 kOhms and should not pose a loading issue in typical user applications.

Screw Fully Retracted

Screw Fully Forward

Position Sensor

Machine Barrel

Hot Runner System

Plastic

Doc001183.ai

Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation

2012-10-12

Synventive eGate Instruction Manual / Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual