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G24 User Manual PDF

1. Ribbon Cable Routing Wire Tie to Secure loose Standard Core 55 083 REV CHANGE 624 ICM plus Modules See Sheet 1 JRK 25414 0620 600621 60622 50622 G24 Right ICM 24TC Module Label Name Descri Length Length Length 1 GD603 G24 ICM Module Assembled 1 1 1 2 GDe0t G24 Input Module 1 2 2 3 6511 019 924 TC Bus Ribbon Cable 1 1 1 4 9620085 Screw M3x0 5 x 10mm Long Panhead Philips 2 2 4 5 9402005 IMF Standoff Thread x22mm Long 8mm Thread Tail 2 2 6 9402006 Standoff Thread x25mm Long 8mm Thread 2 2 7 9520 020 Screw 3 05 x 10mm Long Panhead Philips 2 2 4 GD620 for 12 GD621 for 24 GD622 for 24 TIC Inputs T C Inputs T C Inputs Reference Schematic Peso 716 55 8 Default Settings and Limits G24 Default Limit Default Limit Range Multiple Language Capability English Multiple Languages Power Status Off On Off Automatic Set Point OF 0 932F 0 500C Manual Set Point 0 0 100 Automatic Mode Manual Mode Auto Auto Man Security Level Operator Monitor Operator Supervisor Engineer Security Codes Up One Level at a Time 321 654 Monitor Operator Operator Enter 0 to go Down One Level at a Time 987 Supervisor Supervisor Engineer Tuning Auto tune 0 31 to 27
2. Manual Auto Ties Locked No 260 10 Deviation Alarm 20 Auto Standby 220 Short Detect 440 Time _9 0 120 Tuning Override 0 Power Priority 0 Tip 1 2 Wel eas RES 9955955235 FL Biiiiiiiiierb liiii iii Tip Spare Man Sprue Monitor Press the upper right larger temperature value to drop down the list Change all critical set points by zone or by group Wizard Step 2 Display actual values for the selected zone and expand by pressing the down arrow Change the zone name Wizard Step 1A Undo one or more set point changes Save a Menu Wizard Step 7 Main Top Buttons The main top buttons Off by zone by group global or managed cooling On by zone by group or managed heating Wizard Step 6 Standby to go to the programmed alternate set point programmable by zone Boost temporarily raise the temperature of blocked nozzles to get the material flowing The temperature is returned to normal after the timeout period 19 Button Choices elect Screen Pilot Line SPC Tool Graphic Data Table Setpoint Table EZ Screen Minicontroner Cavity Pro Mold Doctor
3. Dual Input amp Output Control Module ICONNECTO yo P2 Voltage P10 REV CHANGE WHO See Sheet JRK 20412 Cable to Mold Thermo Couples WB00150 or Similar T C Cable Harness Cable to Mold Thermo Couples 6580 021 or Similar USB A mB Cable 800155 or Similar Aux I O Cable Harness to Mold Cable to Modules WB00146 or similar Cable Harness Heaters Heater Connector Cable to Mold SYNVENTIVE 824 Reference Schematic TE 45 G24 Input Control Module Diagram 25 EUM Connector P4 Connector P7 Connector P6 Pin Signal Pin Signal 1 Em 1 14 HO Pin Signal Pin Signal 158 Mini B Shield 2 15 1 11 Not Used 1 in Sigal 3 Signal Gnd 16 2 D Common 12 NotUsed 2 1 4 Signal Gnd 17 Control Disable 3 45 13 12Vde 2 USB DM 5 54 18 4 5 14 12 3 USBDP 6 5Vde 19 ICM A1 5 5 485 15 4 ASB Dir 7 5 485 20 2 6 5 485 16 5 USB GND 8 85485 21 5Vde 7 Reset 17 12Vdc 6 USB Shield 9 Sync 1 22 5 8 4 18 12vdc 10 OM AO 23 Signal Gnd 9 A5 19 1 11 5 2 24 _ Signal Gnd 10 20 Drain2 12 25 Drain 1 13 3 Drain 2 2
4. A Temperature oscillation greater than 1 5 degrees F or 0 75 degrees C Temperature does not make it to set point and the output modulates reduces from 100 Temperature hovers above set point and the output does not reduce to 0 The output of the zone oscillates dramatically especially if it goes to 0 during the cycle CAUTION THE TUNING OVERRIDE SHOULD ONLY BE CHANGED IF YOU ARE HAVING ONE OF THE FOUR EXAMPLES OF TUNING ISSUES LISTED ABOVE NOTE THE ACTUAL TUNING SELECTED BY THE AUTOTUNE PRIOR TO MAKING ANY CHANGES TO EASILY REVERT BACK TO THAT VALUE VIA 400 fa Stndby Boost lt Tip amp Jez screen gt n 1 2 Line Alarm Off On First Selection Second Selection Deviation Percent Output ME Graph Settings Mark Start of Injection 42 1 1 5 4 3 2 1 0 1 58 28 PM 1 58 30 PM 1581 PM 1 58 32 PM 1 5833 __ 1 58 34 4 58 35 PM 4 58 36 PM 1 58 37 1 58 38 PM 1 58 39 PM 1 50 40 PM 1 58 42 PI Average 0 Tip Man Sprue Awerage 16 1 Pause Graph Example of normal control shown above The temperature is controlled to roughly 0 2 degrees F or 0 1 degrees C The percent output is modulating between 8 and 25 to maintain control 28 Thermocouple or Tuning Issue Proced
5. 1 61000 6 2 6 4 4 2 4 3 4 4 4 5 4 6 4 11 Safety IEC 61010 UL 508 UL 873 and CSA 58 10 Hardware Troubleshooting CAUTION ALWAYS LOCK OUT TAG OUT THE AC POWER MAIN CIRCUIT BREAKER BEFORE REMOVING OR INSTALLING TEMPERATURE OUTPUT MODULES CAUTION ONLY TRAINED AND QUALIFIED SET UP OR ELECTRICAL PERSONNEL SHOULD PERFORM THE TROUBLESHOOTING PROCEDURES PROPER TRAINING PROVIDED BY SYNVENTIVE IS A MUST FOR QUALIFICATION TO TROUBLESHOOT THE EQUIPMENT SAFELY CAUTION REPLACEMENT OUTPUT MODULES ARE MUST BE SUPPLIED BY SYNVENTIVE Input Control Module LEDs ICM The G24 has an Input Control Module ICM board that is located on each rack of the enclosure near the rear of the enclosure This board is responsible for communication between the touchscreen the thermocouple cards attached to the ICM and the output cards on that rack There are four LEDs mounted vertically on the ICM located just below the ribbon cable that can be very useful in diagnosing any communication problem that arises The LED light status for each of the four LEDs with Notes listed for each possible condition shown below From Top Note 1 Note 2 Note Note 4 Note 5 Note 6 Note 7 3 USB Green Red Red Off Off Green Green amp Flicker Slow Flash Rough Red CPU Green Green Off Green Off Green amp Green amp Flicker Flicker Flicker Red Red Rough Outputs Green Green Off Green Green Off
6. SS Pin 10 Not Used Group E Option Codes Wire 86 connect to Wire amp 11 G24 ICM Module 8501 CONNECTOR P2 PE 24 4 24Vdc Relay Snub 6 Power Supply 24Vdc Relay NO 4 5 to Hot 1 240VAC oyee Relay Com gt 4 5 Vde Relay NC gt 3 ense AuxIN 24V 2 to Ret 240 Sense AuxIN Com gt 1 SYNVENTIVE 52 552053 REV CHANGE WHO DATE G24 Reference Data amp Tables sese auri System MAINs Supply Function Description Pseudo Core MAINs Supp True or 30A Core MAINs Supp Ph 1 Neon Core Block Core Block Core Block Ph 2 Neon Function Hot Wire Return Wire Ph amp 3 Neon Pwr Supply Pwr Supply R2 MEX R1 R2 R3 USB HUB PS OM 1 OM or 30A 1 R2 Computer PS a ge no somect no connect VO Excitation PS or Core 1 Phase 1 OM 4 notused no connect no connect Core 81 Phase 82 5 30A 3 13 R1 Core 1 Phase 3 OM 6 not used connect no connect Core 2 Phase 1 OM 7 1 R2 Core 2 Phase 2 OM 8 no connect no connect Core 2 Phase 83 OM 9 12 R3 Core 83 Phase 1 OM 10 no connect no connect Core 3 Phase 2 11 L3 R1 Core 3 Phase 83 Note Core Phasing for Large systems may vary to balance loading 12 connect no connect Enclosure Phase Neons Phase 1 Phase 2 Phase 3 Power Supplies a
7. Mold 1628 mnu 2012 11 16 1 41 Mold 4582B mnu Restore Menu 2012 10 16 10 14 AM Tool Room Main Screen Default Mold Doctor Wiring Analysis Thermodynamic Analysis Fault Analysis Historical Mold Performance 8 u Man Sprue Monitor Fully program and configure the controller for optimal use Each step also be done manually in the main screen set e Press Start the Mold Wizard what did the software do ANS Software initializes all setpoints to default settings It also clears zone names and group tabs Why ANS To prepare for a new mold which may have a different zone configuration and or heater wattages Step 1A e Press Start the Zone Analysis what is the software doing ANS Software turns on all zones to determine the zone type and amperage How does it decide between a Tip and a Manifold ANS It uses the zone amperage threshold setpoint How do you adjust the threshold and change the default name for Tip ANS Use the Options selection and then enter the desired threshold setpoint From this page you can also change the Zone Type from Tip to Nozzle or one of the other selections on the list e How do you identify the Sprue 11 ANS the amperage and wattage readings How do you change the name of the Sprue or other zones on the list ANS Touch the e
8. 20 1 25 CONNECTOR 4 System Ribbon Cable CONNECTOR P6 USB a Mini B G24 ICM x x t Module Relay Snub as 5 Relay NO Relay Com Relay NC AuxIN 24V CONNECTOR xy Y P2 SYNVENTIVE CONNECTOR P10 Aux O Sa 5 Reference Schematic Line Voltage 14 77 46 lt 6 LINE HOT 2 26 1 25 CONNECTOR J2 G24 15A Output lt 5 B HOT OUT Module 5 9 5 a 5 2 m lt 4 5 ae CONNECTOR J1 LINE 1 gt gt pao FUSE 297 G24 15A Output Module Diagram 87 Hance Pin Signal Pin 8 Signal 9 See Sheet 1 1 Shieki 1 14 2 2 Shied2 15 0 3 SgnalGnd 16 G24 15A Output Module Schematic 4 Siqnal Gnd 17 Control Disable 40 amp 5 41 5 5Vdc 18 N Reset 5 8 6 5Vdc 19 ICM A1 FUSE i RS 485 20 LINE HOT 6 gt gt our i r3 21 7155 4 RELAY 80208821 IOTOUT 9 Synci 22 5 ae 10 OM AO 23 Signal Gnd FUSE sc m 11 2 24 Signal Gnd is 12 1 25 Drain 1 P41 R40 P42 13 Synca 26 Drain 2 4 Heater Reay 17 a 2 ARET OUT FUSE DELTA MAINs Connect P20 to P21 and P40 to P41 Insert Fuse 21 and 41 WYE M
9. gt CAUTION THE THERMOCOUPLE WIRES ARE NOT RATED CARRY THE POWER LINE VOLTAGE ALWAYS LOCKOUT TAGOUT THE MAIN POWER BREAKER WHEN WORKING ON THE THERMOCOUPLE OR MOLD POWER WIRES gt CAUTION DO NOT USE A HIGH VOLTAGE TEST ON ANY TERMINALS WITHIN THE CABINET WHEN ALL THE ELECTRONIC CARDS ARE INSTALLED THE HIGH VOLTAGE ASSOCIATED WITH THESE TESTS COULD DAMAGE ELECTRONIC CIRCUITS WITHIN THE CABINET gt CAUTION IT IS COMMON FOR OUTPUT TRIACS TO SHORT WHEN A FUSE BLOWS A SHORTED TRIAC CANNOT BE REGULATED AND WILL APPLY FULL POWER TO THE HEATER ALWAYS CHECK A CONTROLLED ZONE THAT HAS A BLOWN FUSE BY ADJUSTING POWER FROM ZERO TO 100 IN THE MANUAL MODE THE VOLTAGE SHOULD GO FROM ZERO TO 240 VOLTS OR FULL VOLTAGE RESPECTIVELY 2 CAUTION WHEN REPLACING FUSES MAKE CERTAIN THAT THE MAIN CIRCUIT REAKER HAS BEEN TURNED OFF E CAUTION WHEN REPLACING FUSES MAKE CERTAIN THAT ONLY SIBA VERY FAST ACTING FUSES ARE USED ON THE OUTPUT MODULES REGULAR FUSES WILL NOT PROVIDE ADEQUATE PROTECTION AND WILL VOID THE PRODUCT WARRANTY CONTACT SYNVENTIVE WITH ANY QUESTIONS Amp Volt Rating Size Notes 15 20 25x 1 25 in SIBA 70 125 40 20 F20 F21 F40 F41 500VAC 6 35 x 32 mm Very fast acting FF 30A 13 32 x 1 1 2 in SIBA 50 179 06 30 F20 F21 500VAC 10 3 x 38 1 mm Very fast acting FF Input Control Bussman GDA 3 15A Module ICM 3 15A Littelfuse 0216 3 15 5 5x
10. Ensure the mold has a connection to ground If the mold is in the machine the normal path to ground would be from the mold base through the platen to Earth ground In the tool room most molds are tested on metal tables sitting on a concrete floor without a connection to Earth ground In both cases Earth ground is required to ensure personal safety and to drain electrical noise The temperature is moving faster than it is thermally possible An example would be immediate temperature readings of 400 420 380 410 etc This indicates that the temperature value reported is not correct To solve the problem install a ground wire from the negative thermocouple wire typically the red wire to the best earth ground available which could be electrical ground inside the cable connector Do not ground already grounded thermocouples Grounding a grounded thermocouple can cause a constant lower temperature value to be reported If you are unsure ground the thermocouple and closely watch the temperature rise of each zone when power is applied Temperatures that do not move as expected would indicate a double ground 31 Select Category Program Screen Paths Job Information Setup Limits Menus Diagnostics Pdf Reports Windows Diagnostics Continued Swap T C inputs not recommended but can be useful in an emergency to fix miswired thermocouples The power connections are hard wired and cannot be changed using sof
11. Screen path choices Most Popular e Pilot quick review of the system color coded for the group selected Bar graph display two variables for the group selected Line graph display two variables for the zone selected SPC statistical display of one variable for the zone selected Tape display one variable for the group selected Tool Graphic load a picture and identify change the parts visually Data Table All values shown in a table with quick change shortcuts Setpoint Table quick change shortcuts displayed in a table format EZ Screen the best screen for initial use Minicontroller table like display with easy group temporary zone selection modification Cavity Map create a dynamic cavity chart that can be changed from the A to B side of the mold for up to two faces of a stack mold e Mold Doctor shortcut to advanced diagnostics 20 Gear Button 3 Select Category Program Screen Paths Job Information Setup Limits Menus Diagnostics Pdf Reports Windows Program Screen Paths Select the screen path or press and hold each button until the assignment list appears Job Information e Enter information that will be saved on the reports menus or other saved items Setup Configure Remote 1 cover the three most common interlocks to prevent running without the water Okay to Run to prevent cold movement that may bend break the va
12. PROTECTED BY THE BUILDING SUPPLY IN ACCORDANCE WITH LOCAL AND NATIONAL WIRING REGULATIONS 2 Quick Start Guide e Basic controller programming and use e Quickly enables use of the controller Quick Start Guide 24 Mold Doctor cow Am cow oe BERE D o iol LI mr oon u o a s CERTE A Tins Press and hold to Select Screen Select EZ Screen Check Allow Changes Rotate Auto Manual Monitor Locked Press Setpoint apply by zone or by group Toggle On or Off by zone or by group 006006 10 3 New Mold Wizard Startup Wizard Existing Mold New Mold Wizard Start the Mold Wizard Select a Menu Menu Selected Default mnu 2013 07 26 5 17 PM Default mnu Step 1 Identify Zones in the Mold Setup 0130728 PM Step 4 Setup the Mold Startup Functions Step 5 Setup the Zone Monitor Functions Step 6 Heat the Mold Step 7 Save a Menu Automatically Tune the Zones Automatically Engage the Zone Leak Detection Automatically Engage the Heater Failure Detection
13. See Sheet 1 205412 2 2 XLR Connector XLR Female WB00159 24Vdc Computer Outlet P3 Wire 6 _ ee Wire 7 Pin 3 424Vdc Pin 1 Mdc Pin2 1 24 Pin2 awe 5 Not Used Pin 5 No Connection Not Used Pin 6 WB00152 24Vdc Computer Power Cable G24 Enclosure End G24 Computer G24 Enclosure Black End ct GND Pini White Computar White 2 Shield 1 8501 037 24Vdc 24Vde Power Supply 24Vdc 0 Vdc to Hot 1 gt 240 Connection Soldered Wire 23 View View Sokdered Wire Connection Ven to Ret 3 240VAC Senses 49 CONNECTOR P6 USB Mini B 6580 022 USE AmB Cable 50 G24 USB no HUB Diagram Comets 6580 029 Cable arsa REV CHANGE WHO DATE G24 USB HUB Diagram See Sheet 1 JRK 203412 8501 036 PE 12 WB00157 6580 028 to 12Vdc 12 Vde Comedor 1 gt 240 e PS Cable E PI NE 2 to 1 ien 0 Vdc HosTI USB Cable to Ret 3 gt 240 Sense 6580 021 NB M Sense USB AmB ___ Every external USB Cable must Cable have a ferrite on each end i 6580 027 6580 024 Connect 8605 002 4 Port 8605 003 7 Port 6 eee mi A BCable Chain USB HUB USB Reference Data Vde
14. Rely ONG ceni c Outputs 0 to 30VAC Vdc 3 0A max Rey NO Pns Bom Output Fuse 32V Relay Out Snub Pin 6 G Group Option Codes Wire 13 connect to Wire 16 G24 ICM Module 8501 037 CONNECTOR P2 PE 24Vdc 1 24Vdc Relay Snub Power Supply 2 gt 24vdc Relay NO 3 gt 0 Vdc Relay Com to Hot Ho ayNC 7 5 Sense uxIN 4 to Ret 3 gt 240 6 Sense AuxIN Com JRK 20012 G24 Reference Schematic T7 51 Not Used Pin 6 24 Mates to ICM 1 P2 Aux IN COM Signal lt Pin2 Yellow ssa z REV CHANGE WHO DATE G24 Aux 1 In 1 Out Diagram See Sheet 1 JRK 20412 Up to 1 Inputs and 1 Output Inputs Energized 10 8 to 30 VAC Vdc Used with Model Option Codes Not Energized 0 to 1 0 VAC Vdc 5 amp Outputs 0 to 30VAC Vdc 3 0A max Group amp W Output Fuse 32V Group option Codes Wire 6 to Horn Horn TH Ground Bar Ground Bar Ground Bar Ground Bar Pt HA 10 Female Contacts Pini ICM 1 IN White Pin gt ICM INCOM bia Pin 2 gt Not Used Pin 7 gt Not Used orange Pin3 gt Excitation 24Vdc 40 55 Black Pin 8 gt Excitation COM Pin 1 White Relay Out lt Pin3 Pin4 NotUsed OANO Ems Ded Pins Not Used Relay Out Snub
15. Temperature Set Point Maximum Limit 932 0 932F 0 500 Manual Percent Maximum Limit 100 0 100 Temperature Deviation Alarm Set Point 20F 1 999F 1 537C Boost Set Point 20F User Selectable 0 932F 0 500C Boost Set Point Limit 50F 0 932 0 500C Range is bipolar Boost Time Set Point 60 sec 0 300 sec Trim Set Point OF User Selectable 0 932F 0 500C Trim Limit 100F 0 932F 0 500C Standby Set Point 220F 0 932F 0 500C Standby Group None User Selectable Thermocouple Pinch Detection Time 0 0 5 min 1 54 minutes 54 minutes disabled T C Pinch Alarm Degrees F or C Selectable Thermocouple Input J JorK Alarms Latched Disabled Enabled Disabled Operator ID None Enter Operator ID s to enable Material Protection Disabled Enabled Disabled Material Protection Time in seconds 0 0 999 Heater Resistance Monitoring Disabled Enabled Disabled Heater Wattage Monitoring Disabled Enabled Disabled Watt High Alarm 8000 0 8000 Watt Low Alarm 0 0 8000 Critical Over Temperature Alarm 932F 0 932F 0 500C Outputs on Power Up question Ask Always On Ask Always Off uninterrupted running Graph Setting Defaults Auto Scaling User Selectable Seconds Per Update 1 5 seconds 65 5 seconds Time Compression 14 1 1 1 300 Scale Max both 100 999 999 Scale Min both 0 999 999 Tool Pictures None User Generated Database Max File Size 1 Meg 1 100 Meg
16. The temperature of the zone is below the deviation band Open Fuse Alarm Fuse on module bad Deviation High Alarm The temperature of the zone exceeds Heater Short Alarm The heater is shorted or exceeds the maximum rating of the module Thermocouple Open Alarm The connection is broken Heater Open Alarm The heater connection is broken Thermocouple Reversed Alarm The T C connection is wired Co Uncontrolled Output Alarm The module has an unregulated to at some point output Thermocouple Short Alarm The TIC is pinched or the pm controller thinks that it is pinched gt 98 output must see 20 A Ground Fault 11C rise in 5 minutes Resistance Monitor Alarm Predict Heater Failure The resistance of the heater has deviated by more than 40 from the Baseline resistance pz Watt Alarm Plastic Leak Detection The output for the zone has exceeded the limits that E nave been entered High Alarm 4 may be due to Plastic Leak Detection Low Alarm may be due to loss of a parallel heater System Alarms quc Critical Overtemp Alarm The temperature for a zone has Denotes that the alarm is active at this exceeded the alarm limit time Done Material Protection Alarm The machine has stopped x Denotes that the alarm turned on when cycling and the controller has gone to Standby indicated
17. Tip 1 F 410 O 1 DF 20 Tip O 1 DF 20 Tip 3 F 415 96 17 0 0 1 DF 20 4 F 415 17 0 0 1 DF 20 Adding Values 1 instruction causes named Values csv to be created the Network folder This file is updated recreated based on the settings described above Only the last file is available This is a comma separated values file and may be imported directly into Microsoft Excel Microsoft Word and others All of the values for all of the zones are always included in every Values file Each zone is on a separate line Like the Setpoints file the zone ID is followed by a space followed by the zone number within the ID This is followed by a comma After the comma is a list of all of the following values in the order Zone name Process value Active percent output Amps Volts Auto Manual output mode status 0 auto 1 manual Zone On Off status O off 1 Alarm status Zone Status 12 Ground Fault 2 Zone Locked Alarm status is a binary number with the following bit assignments Assignment Thermocouple Open Thermocouple Reversed Uncontrolled Output Heater Short Heater Open Open Fuse Deviation High Deviation Low Thermocouple Short Heater Resistance 10 Zone Off 11 Manual Mode 12 Auto Standby 13 Control Inhibit 14 Undefined 15 Watt alarm eight 512 1024 2048 4096 8192 16384 32768 G24 Zone status is a binary number with the followi
18. 20 mm Relay Output 250 VAC Schurter 0001 1009 F1 UL recognized CAUTION THE SAFETY SYSTEM INCORPORATING THE G24 IS THE RESPONSIBILITY OF THE ASSEMBLER OF THE SYSTEM CAUTION IF THE EQUIPMENT IS USED IN MANNER SPECIFIED BY SYNVENTIVE THE PROTECTION BY THE EQUIPMENT MAY BE IMPAIRED A CAUTION DISCONNECT SYSTEM FROM MAINS VERIFY EQUIPMENT IS SAFE AFTER REPAIR MEASURE RESISTANCE BETWEEN EACH MAINS SUPPLY CONDUCTOR AND THE PROTECTIVE EARTH CONDUCTOR AND ENSURE THERE IS NOT A SHORT CIRCUIT MEASURE THE RESISTANCE OF THE PATH FROM AN ACCESSIBLE ENCLOSURE POINT TO THE PROTECTIVE 7 CONDUCTOR TERMINAL THE MAINS SUPPLY PLUG WIRING AND VERIFY IT IS LOW ENOUGH COMPLY WITH APPLICABLE STANDARDS 4 wire Standard 5 wire Standard Phase North American European IEC 60446 L1 Red Brown L2 White Black L3 Black Gray Neutral Blue Safety Ground Green Green Yellow CAUTION BEFORE APPLYING AC LINE POWER THE CONTROLLER CHECK ENSURE THAT THE AC LINE POWER MATCHES THE POWER RATING INDICATED ON THE LABEL ATTACHED TO THE REAR OF THE G24 ENCLOSURE CONFIRM THAT THE AC LINE POWER MATCHES THE CONTROLLER CONFIGURATION OF DELTA OR WYE STAR CONFIRM THAT THE ACTUAL VOLTAGES DO NOT EXCEED THE CONTROLLER RATING THE INPUT POWER WIRING IS CONNECTED PROPERLY AND THAT THE CONTROLLER IS PROPERLY GROUNDED INCORRECT WIRING OR APPLICATION OF VOLTAGES THAT EXCEED
19. In the Existing Mold selection area touch a Menu from the list and then press Restore Menu e Briefly explain the shortcut to Mold Doctor and the four tests ANS In the Tool Room selection area press Mold Doctor or any one of the other items This will take you to the Mold Doctor screen ANS Wiring Analysis selection This tests each individual zone for wiring problems Each zone is heated individually during this test ANS Fault Analysis selection This test is similar to Wiring Analysis except that it does not check for cross wiring of zones All zones are heated together during this test It is normally run after the tool is known to be wired correctly ANS Thermodynamic Analysis selection This test reports the heating cooling rates resistance and average power consumption of all zones except those in Manual mode or locked off Diagnose difficult problems with quantitative data ANS Historical Mold Performance selection This test compares any two Thermodynamic Analysis tests Data is then displayed to indicate which data has changed and by what percentage The Wizard guides the user through a complete controller configuration Each step in the Wizard can be done manually using the various control screens Now that the controller is configured and potentially heating it is best to review the alarm page three major sections and the reset buttons 14 4 Alarms and Troubleshooting mm VIA 4001 i Startup Wizard Minic
20. KCN RET SYNVENTIVE 24 Reference Schematic 5 0259 4 MAINS INPUT G24 ENCLOSURE WIRING 3P WYE MAINS MAINS L1 MAINS L2 7 MAINS L3 MAINS Neutral Distribution Blocks as required REV CHANGE WHO DATE See Sheet 1 JRK 203412 Core Blocks MAINS PE ON 2 Power Supply L2HOT Output Modules amp ICM Modules L3HOT Page 14 for T R1RET Line Phasing 2 Information 9 R3RET el H to DRAIN e to GND je L1HOT L2HOT 5 L3HOT od HASSIS ans ROUND Power Supplies FAN iced amp Neon Indicators SYNVENTIVE PESo259 44 552053 60305 lt 6 Shield lt 5 5VCOM lt 4 5 lt 3 5Vde lt 2 5V COM lt 1 Shield 8501 035 Distribution Blocks as required G24 Core Block Diagram 8511018 Ribbon Cable 112020 Right Si Pin Signal Pin Signal 1 She 2 2 Shield 2 15 3 Signal Gnd 16 4 Signal God 17 5 18 6 4506 19 7 RS 485 20 8 ray Ribbon Cable or Black Ribbon Cabl s smer 02 10 OMAD 23 11 Syne 2 2 12 25 13 Syne3 26 CONNECTO J2 P4
21. Off Flicker Flicker Flicker Flash Thermocouples Green Green Off Green Green Green Off Flicker Flicker Flicker Flicker Flicker Notes 1 Normal operation communicating with Operator Panel T C input module Output Module and running PID in application mode While all four of these LEDs flicker the USB LED flickers at a somewhat slower rate than the other three 2 Red USB flashing every 2 seconds ICM is not communicating with the touchscreen via USB but is otherwise running normally 3 USB lines held low by malfunctioning touchscreen or USB hub preventing CPU from running Disconnecting the USB cable will allow CPU to run but USB communications will still need to be debugged and reestablished 4 Connected to touchscreen and USB communications are OK but G24 software is not running on the touchscreen The normal state when in Express Update but BEFORE sending down data files Normal software update using Express Update while data is downloading Rare state indicating software encountered a problem on power up preventing application to run correctly 59 Remote Input Output LEDS Just below the four ICM LEDs are two more LEDS that indicate the status of remote inputs and outputs if remote inputs and outputs have been ordered The LEDs are located between the USB cable connector and the green Remote Input Output connector below the Input Control Modules LEDs The first remote input and output are found on the first ICM b
22. THE CONTROLLER RATING WILL RESULT IN SEVERE DAMAGE TO THE CONTROLLER CAUTION ENSURE THE PROPER AMPERAGE AND INSULATION RATINGS CABLES ARE USED WITH THE G24 CONTROLLER PER THE CHART BELOW ANY QUESTIONS PLEASE CONTACT SYNVENTIVE Amps Insulation t N Connector lotes i Refer to unit label for amperage rating Mains Input 309 Refer to circuit breaker datasheet Refer to unit label for amperage rating Power Output 300 Refer to connector datasheet T C Input 1 300 Refer to connector datasheet Remote 5 300 Mold ID 1 300 USB 1 300 Ethernet 1 300 RS 232 1 76 300 Operator Panel Power Input 2 309 CAUTION THE CIRCUIT BREAKER SIZES ARE DETERMINED TIME ORDER ENTRY BASED UPON INFORMATION SUPPLIED BY THE USER CIRCUIT BREAKERS ARE LOCATED ON THE BACK OF THE CONTROL ENCLOSURE T current R resistance Calculations Circuit Breakers Reasonably Balanced Load Across the Phases Circuit breaker Delta Power 240 VAC Three Phase Total Tool Amperage 1 73 1 25 Circuit breaker Delta Power 240 VAC Single Phase Total Tool Amperage 1 25 Circuit breaker Wye Power 230 VAC Three Phase Total Tool Amperage 3 1 2 Circuit breaker Wye Power 230 VAC Single Phase Total Tool Amperage 1 2 CAUTION FAULT CURRENTS IN EXCESS OF THE CIRCUIT BREAKER RATING MUST
23. but is not active at this time CAUTION ALWAYS LOCK OUT TAG OUT THE AC POWER MAIN CIRCUIT BREAKER BEFORE REMOVING OR INSTALLING TEMPERATURE OUTPUT MODULES CAUTION ONLY TRAINED AND QUALIFIED SET UP OR ELECTRICAL PERSONNEL SHOULD PERFORM THE TROUBLESHOOTING PROCEDURES PROPER TRAINING PROVIDED BY SYNVENTIVE IS A MUST FOR QUALIFICATION TO TROUBLESHOOT THE EQUIPMENT SAFELY CAUTION REPLACEMENT OUTPUT MODULES ARE MUST BE SUPPLIED BY SYNVENTIVE 16 Synventive General Troubleshooting Turn Main Disconnect 1 Using a multi meter check resistance from pin to pin at the mold Thermocouples should read 3 75 ohms at room temperature 100 ohms or greater would be a candidate for replacement Heaters should read greater than 80 ohms 3 amp module 16 ohms 15 amp module and 8 ohms 30 amp module If there is no continuity open line broken connection open heater or open T C Compare actual resistance to specification resistance 2 Check resistance from pin to ground at the mold Heaters only no continuity open line good Some resistance is bad heater shorted 3 Reattach the cable to the mold detach the cable from the controller Check resistance from pin to on the cable Thermocouples should read 3 75 ohms at room temperature 100 ohms or greater would be a candidate for replacement Heaters should read greater than 80 ohms 3 amp module 16 ohms 15 amp module 8 ohms 30 amp module If there is
24. conveyer or have the robot place the part in position B for inspection and not stop the machine When complete press the arrow to the right button to go to Step 4 Step 4 Why would you want to use Sequence Start ANS To prevent burning the material prior to starting the machine and ensure the manifold expands properly to hold the seal and protect against plastic leaks Why would you want to use Even Heat ANS Even Heat ensures that all zones heat within 20 degrees F or 11 degrees C of the coldest zone This helps prevent the material in the nozzles from degrading while waiting for the manifold zones to heat up NOTE Even Heat will not work the first time the mold is powered due to the Auto Tune routine The function will work the second time the mold is heated following a menu restore or power cycle to the controller Why would you want to use Sequence Cool ANS This is required for multi tip nozzle manifolds or similar sensitive molds to prevent plastic leaks Why would you want to use Even Cool ANS This is another option to better control the contraction of the mold components When complete press the arrow to the right button to go to Step 5 Step 5 How does the Heater Watt Alarm detect plastic leaks ANS Plastic leakage creates a heat sink resulting in more power being required to hold setpoint How does the Heater Resistance Monitor predict heater failure ANS Use the example of an incandescent light bu
25. no continuity open line broken connection open heater or open T C The connection is broken in the cable set or the connectors pins are not making contact 4 Reattach the cable to the mold detach the cable from the controller Check resistance from pin to ground on the cable Heaters only no continuity open line good Some resistance is bad heater shorted The wires are either shorted in the cable set or the connectors are shorted to ground CAUTION BE SURE MAIN POWER IS LOCKED OUT TAGGED WHEN SWAPPING ANY ELECTRICAL COMPONENTS 5 At this point if everything is fine the problem is in the controller 1 turn Off main disconnect lockout tag out 2 locate problem module 3 check fuses on module 4 swap bad module into a known good location 5 turn main disconnect 6 test the zone If the problem follows the module bad module If the alarm stays with the original zone the problem is between the module and the connectors on the rear of the enclosure 6 If the problem is not explained or you need spare parts please contact Synventive Example multi meter from Fluke Model 27 11 28 11 17 mm VIA 4007 Startup Wizard Minicontrotier E Alarm Om On P 4 gt Clear Zone Alarm History Select Alarm Display Zone Alarms zone Alarm History Alarm History System Alarms and Status Reset Critic
26. 24 Temperature Controller User Manual Version G1 05 January 2015 ES ynventive molding solutions business of BARNES GROUP INC Table of Contents 10 11 12 Safety Quick Start Guide New Mold Wizard Alarms and Troubleshooting Operation Control Optimization Network Access Hardware Default Settings and Limits Specifications Hardware Troubleshooting Maintenance Contact Information 10 11 15 19 28 32 39 55 57 58 60 61 1 Safety To protect the operator at the work place ensure that all safety devices installed on the machine and mold are functioning correctly Never disable or by pass a safety device Follow the machine and mold manuals for safe procedures and safety checks Reference to Standards Important For machine or mold rebuild repair or maintenance lockout tag out procedures must be followed as recommended in ANSI 224 4 1 1982 The American National Standards Institute and as specified in OSHA 29CFR PART 1910 14a7 Throughout this manual references are made to various standards ANSI American National Standards Institute OSHA Occupational Safety and Health Act and CE Conformity in Europe for safety or operating protocol We recommend that these standards be the minimum used If there are more stringent local standards they must be followed Personal Protection The operator must wear safety glasses face shield heat resistant glo
27. 8 16 0140914 G24 Reference Schematic Pages 1 Front Page p2 System Block Diagram p3 MAINs 3P Delta Diagram p4 MAINs 3P N WYE Diagram p5 MAINs 3P WYE Diagram p6 Core Block Diagram p7 ICM Diagram p8 15A Output Module Diagram p9 T C Input Module Diagram p10 Computer Power Diagram p11 USB Diagram p12 242 Aux Diagram p13 1 1 Aux I O Diagram p14 Reference Data amp Tables p15 30A Output Module Diagram p16 ICM plus T C Input 40 DATE 20 12 G24 System Block Diagram Voltage VO P S Optiona 24 4 Computer 24 4 i H E Power Supply USB Power Supply Cable Top Area Hos Power Supply Cables i i AC TM i LINE 24Vdc External i MAINS i i INPUT MAINS Cables for Mold i b nput i CABLE amp Distribution AC LINE ithermo Couples VOLTAGE Dual Output Modules 1 to 12 Cables for Mold i i LINE Heaters i Voltage i 5Vdc Block Core Block Area i FAN i 1or2 Power Supply more Core Blocks and Adapter for more Zones i Cables for Mold Control Input Module Thermo Couples Dual Output Modules 1 to 12 lit Cables for Mold Heaters SVdc Block Core Block Area more Core Blocks an more Zones 605 MAINS INPUT MAINS PE MAINS L1 MAINS L2 MAINS L3 R
28. AINs Connect P20 to P22 and P40 to P42 Remove Fuse F21 and F41 G24 15A Output Module PCB 9 47 550053 s REV CHANGE WHO TDATE G24 ThermoCouple Input Module Diagram See Sheet 1 JRK 2012 Connector J1 Pin Signal Pin Signal 1 D Common 11 Not Used 1 2 D Common 12 Used 2 Typical 3 5Vde 13 312 4 uS 4 5 14 12 3 2 G24 TC In 8 9 xx wae 5 85 485 15 A Common 32 5 iz 6 RS485 16 A Common 25609 Module 3 xx 77 Reset 8 298 9 5 19 Drain 1 WS 10 20 Drain2 xxl Zs 5 5 a o9 QU xx Connector J6 Oxy Pin Signal Pin amp Signal p 1 TCin 1 20 Ten TCin 2 21 ToIn 2 3 Tcin 3 22 4 23 4 5 5 24 5 6 TCin 6 25 5 7 26 7 XO 1 cx 8 8 27 8 E 9 Chev 28 CJ Volt E 10 Sink 1 29 C Volt 25 11 C Com 30 9 72 E 52 12 9 31 TCIn 10 2 29 13 TCin 10 32 TCin 11 59 14 TCh 11 TCIn 12 2 J 95 15 12 34 Foha 2 3 55 16 35 1 4 ote 28 17 109434 36 1 15 d E 18269 15 37 68 36 wee 19 FORS Jee Inputs 13 to 16 are not used 48 65053 5 REV CHANGE G24 Computer Power Diagram
29. CTED EQUIPMENT REQUIRING EXTERNAL SWITCH OR CIRCUIT BREAKER CB USE A SWITCH OR CB OF APPROPRIATE AMPERAGE AND VOLTAGE RATINGS TO SAFELY HANDLE THE SYTEM S LABELED AMPERAGE AND VOLTAGE RATING PLACE THE SWITCH OR CB NEAR THE EQUIPMENT gt CAUTION ALL POWER UP PROCEDURES SHOULD BE DONE BY A TRAINED IFIED SETTER OR ELECTRICIAN PROPER TRAINING PROVIDED BY SYNVENTIVE IS A MUST UALIFICATION TO SET UP THE EQUIPMENT SAFELY e 2r gt o E CAUTION BE SURE MAIN POWER IS LOCKED OUT TAGGED OUT DURING PRE START P PROCEDURES c PLUG LOCKOUTS Universal Plug Lockout Cinch Bag Lockout Grainger Item 57831 Master Lock 4531 DIN Rail MCB LOCKOUTS Applied to Circuit Breaker Internal Pin Lockout 4 3 Grainger 2VU32 Miniature Circuit Breaker LOCKOUTS Factory Installed Style Lockout gt Field Installed Style Lockout 45 Applied to Circuit Breaker Direct operated Molded Case Circuit Breaker MCCB LOCKOUTS Field Installed Style Lockout 22 Applied to Circuit Breaker Rotary Handle Operated Molded Case Circuit Breaker LOCKOUTS Rotary Handle Style Lockout Applied to Circuit Breaker Handle CAUTION MAKE CERTAIN THAT EACH CONNECTION THERMOCOUPLE CIRCUIT IS BETWEEN EITHER TWO RED OR TWO WHITE WIRES DO NOT CONNECT RED AND WHITE THERMOCOUPLE WIRES TOGETHER EVEN IF THIS MAY APPEAR TO CORRECT AN OPERATING PROBLEM
30. Database Seconds per Update 1 1 1 1 300 1 Database What to do File Keep Newest Keep Newest Keep Oldest 56 Create New Report Length 1 Hour 1 48 Hours Report Type View View Print 57 General Calibration Accuracy Control Accuracy steady state Power Control Time Process Sampling Control Algorithm Degrees F or C Operating Range Output Voltage Standby Temperatures Remote Input Relay Output Input Specifications Thermocouple Cold Junction Compensation External Resistance Temperature Variation due to T C length Electrical Specifications Input Power Frequency Ambient Temperature Humidity Range Output Module Range Internal Communications Performance Standard US Canadian and International Designed to Meet 9 Specifications 0 2 F 0 1 C 0 05 C 8 3 msec 120 times per second at 60 Hertz 50 msec 20 times per second Automatic self optimizing manual override Field Selectable 0 932 F 0 500 C 0 240 VAC Phase angle fired 0 196 resolution User selectable 0 932 F 0 500 C 24 VDC Rated at 24 VDC Fused 3 amp Type J standard Type K selectable Internal to enclosure 10 Meg Ohms None 180 265 VAC Delta Wye phase voltage 47 53 Hz 57 63 Hz 32 122 F 0 50 C 10 9596 non condensing 2 zone 15A per zone 3600W 240 VAC 1 zone 30A per zone 7200W 240 VAC Industrial USB 2 0 CE Mark
31. EV G24 ENCLOSURE WIRING DELTA MAINS CHANGE WHO DATE Distribution Blocks as required BOTTOM TOP IN OUT qs UL e L1HOT CIRCUIT R1RET preesse ot 4 L2HOT R2RET D L3HOT t R3RET T to DRAIN 9 to GND ie L1HOT R1RET SYSTEM CHASSIS 9 L2HOT GROUND R2RET L3HOT R3RET FAN RET See Sheet 1 JRK 203412 to Core Blocks Power Supply Output Modules amp ICM Modules See Page 14 for Line Phasing Information to Tops Fans Power Supplies amp Neon Indicators P ES 0250 42 650537 REV CHANGE WHO DATE G24 ENCLOSURE WIRING 3P N WYE MAINS JRK 200412 BOTTOM Distribution Blocks as required IN 507 MAINS L1 p CIRCUIT L1HOT to Core Blocks 5 Power Supply g MANSL2 p BREAKER L2HOT Output Modules 2 amp ICM Modules 543 m lt vs L3HOT See Page 14 for R1RET Line Phasing IAINS Neutral Ste R2RET Inf ti MAINS Neutrai 5 2 information 8 NEUTRA G MAINS PE H to DRAIN m to GND 9 L1HOT 2 L2HOT BER GROUND Power Supplies COR RET amp Neon Indicators FAN R3RET
32. ON repestedly until the display shows or ip n the upper right comer and LO L in the center See Figure S Press V A to set the flow rate at 727 SETUPgom L which the Normally Open switch contact will To tum off this set press and bold the display shows OFF Semp Mode wil coulis unless you exit Set Hi Limit Flow Switch Point Enter Setup Mode rc poge 3 Press ON SETUP gpm e shows Ipan Ht the center set the flowrate at L anally Open switch contact will Clow Pres ON when desired value i displayed 6 757 display shows OFT and prous ON to set Setup Mode will contame unle s you exit Wire Color Black Function DC Ground and for Analog Yellow DC 8 to 28V Red Not used Blue Not used Flo pur Temp Analog Voltage Output Green Relay Common Brown Normally Closed Gray Relay Normally Open Smartflow sensor Cable wire definition table 24 ICM 1 Input Standby White Yellow CM 2 Input Control Allow inhibit White Yellow 24 Volt DC Supply Voltage Black Orange CM 1 Output Okay to Run Gray Brown 6 4 Flow Meter Control Allow Inhibit Interlock Status of Okay to Run ynve n t All unlocked speed be 2 A molding solutions Om Within devia
33. OPERLY TRAINED IN ELECTRICAL SAFETY AND AUTHORIZED TO WORK ON THE CABINET THERE ARE HIGH VOLTAGE ELECTRICAL CIRCUITS INSIDE THE CABINET CAUTION ALWAYS LOCKOUT TAG OUT THE MAIN POWER BREAKER BEFORE OPENING THE CONTROLLER ENCCLOSURE DO NOT CLOSE THE MAIN BREAKER IF THE CONTROLLER CABINET IS OPEN gt CAUTION ALL CONTROLLERS HAVE A PROTECTIVE CONDUCTOR TERMINAL EARTH LUG ON THE REAR OF THE CABINET WITH 6AWG 16 GREEN WIRE CONNECT THE TERMINAL TO EARTH THIS IS A SAFETY WIRE AND MUST BE INCLUDED IN THE CONTROLLER SETUP UNAUTHORIZED PERSONNEL SHOULD NOT BE ALLOWED ACCESS TO THE INTERIOR OF THE CABINET CAUTION CONTROLLER USING J THERMOCOUPLES SHOULD SET FOR A TEMPERATURE HIGHER THAN 400 DEGREES C 760 DEGREES F AT THIS TEMPERATURE J TYPE THERMOCOUPLES CAN BEGIN TO OXIDIZE AND BECOME NON LINEAR LOSE THEIR CALIBRATION OR REPEATABILITY IN ADDITION MOST THERMOPLASTIC RESINS ARE MOLDED AT LOWER TEMPERATURES HIGHER TEMPERATURES COULD CAUSE THE MATERIALS TO DEGRADE 3 2 CAUTION LIFT THE G24 SYSTEM ONLY WITH MECHANICAL LIFTING DEVICE SUCH A MANNER THAT THE LIFTING DEVICE S WEIGHT BEARING SURFACES MAKE CONTACT WITH THE BOTTOM OF THE G24 SYSTEM S PEDESTAL THE ENTIRE WEIGHT OF THE G24 SYSTEM NEEDS TO BE SUPPORTED BY THE PEDESTAL DURING ANY MOVEMENT THERE ARE NO HANDLES OR LIFTING POINTS ON THE SYSTEM OTHER THAN THE PEDESTAL CAUTION FOR PERMANENTLY CONNE
34. al 2 Overtemp Alarm T Status of OK to Run taset Monitor Zone Systemis OKtoRun Configure Zone Alarms Man Sprue Monitor Middle System Alarms and Status section e This section covers items such as the Wizard Okay to Run Boost Standby and remote inputs section will indicate when each status alarm is activated cancelled deactivated completed Bottom Status of OK to Run e All zones that are unlocked must be at set point and without any alarms All monitor zones must be within range and all inputs must be in the state to allow normal operation e If the system is not OK to Run the reason s will be displayed in this section Right Side Clear Reset Buttons Configure Zone Alarms Clear buttons Zone Alarm History System Alarm History This will clear the information on the alarm page and the reports Active Historical Alarms selection and historical graph e Reset buttons Critical Overtemp Alarm and Monitor Zone Alarm required acknowledgement to resume operation and clear the programmed action 18 Jez screen 9 e V Al 400 Pilot 5 Operation On standby Boost 4 Zoom FA v Temperature 360 Setpoint 400 340 Manual 0 0
35. ays have an up to date collection of setpoints If this box is left empty the file will only be updated when an external computer requests that the file be generated Transfer file data in Degrees C Process values and setpoints are generated in Degrees F regardless of what the G24 screens indicate Check this box to transfer the information in Degrees C Enable network access to the Deviation Setpoints Check this box if it is desired to add deviation setpoints temperature alarm settings to the AllSetpoints txt file Exchange data in True csv file format AllSetpoints txt file normally includes a colon after each zone name preceding the values for that zone Check this box to replace the colon with a comma Import the AllSetpoints txt file from USB Press this button to transfer the AllSetpoints txt file to the G24 from a USB drive These setpoints will override what is currently in use in the G24 Write the Values csv file to USB Press this button to load the latest values to a USB drive This button does not update the Values csv file that is in the D G24 Network directory Write the AllSetpoints txt file to USB Press this button to load the latest setpoints to a USB drive This button does not update the AllSetpoints txt file that is in the D G24 Network directory Path Button Setup Launch an application on G24 screen startup At times other vendor software may be integrated on the G24 screen If there is integrated sof
36. d cleaning ever be required please contact Synventive Check Power and Thermocouple Cables Only check cables with the circuit breaker locked off It is very important to routinely check all the cables on the rear of the cabinet These routine checks should be carried out by a qualified electrician every six months Make certain all the thermocouple and power cable connectors are well seated and all latches are secured in their locking positions Inspect all cables for possible wear and or abuse that would necessitate replacing a cable If a cable pulls away from its housing strain relief the cable should be replaced immediately Any visible nicks or flat spots in cables should be viewed as good candidates for replacement If any part of a connector base or hood appears loose the repair should be done immediately or replaced if necessary Check the Earth Ground Connection Earth ground should only be checked with the G24 circuit breaker locked off Checking the earth ground connection should also be performed every six months Installation and connection of the green yellow green Europe earth wire from the G24 cabinet lug to ground is a MUST In most locations it is a LAW to have all the safety connections that are required by the local electrical codes This connection should be routinely checked not only for connection but for continuity Check the Operation of Cooling Fans Every six months check the internal fans of the G24 for operation Us
37. egrees F would get a 23 Observe the control The higher the tuning override value the more temperature lag will be compensated for by the controller If this controller is dedicated to the mold you can leave the manual tuning value and each time the controller is powered the same control will be provided The tuning value is saved in a menu 29 Temperature Range 6 F 3 C Tuning Override 22 Temperature Range 3 F 1 5 C Tuning Override 21 Temperature Range 12 F 6 C iri Rehge 946 25 1 Tuning Override 24 3 control stabilizes but the parts are worse and the of power is moving dramatically up and down This indicates that you have low mass or small diameter nozzles Enter a tuning value of 27 and observe the control You will see that the output swings are less pronounced It is also suggested to use a Power Priority value of 3 to stabilize the output The lower the Power Priority number the less power stabilization Temperature Range On Cycle Shear Heat aaa pes Rue Sa Heat Tuning Override 10 Irregular Part uning Override a a a Power Priority 3 Stable Parts and Stable 4 actual temperature is higher than the set point and the output is always at 0 This zone is being heated by another zone This is not a tuning or T C issue 30 Step 2B Results Thermocouple Issue 1
38. emembered Output and Copy Output explain how both work Check Allow Changes Enter the temperature setpoints for each zone Point out that a setting can be changed for the selected zone or any of the individual groups When everything is set properly press the arrow to the right button to go to Step 3 Step 3 This step is only displayed if there is one or more Monitor zones Why would you have a Monitor zone ANS A Monitor zone is used to provide a High and or Low alarm setpoint for a feature such as mold water temperature What happens if the system is run with the water off ANS It is possible to burn out water seals gaskets burn out valve gate seals gaskets potentially shift mold components slides cores and likely make bad parts among other potential problems A High alarm would protect against the above items Why would you want to trigger on a Low alarm ANS If the water is too cold the mold can sweat 12 Check Allow Changes to setup the zone and alarm action NOTE If the controller is to automatically go to Standby or Inhibit then you must also automatically stop the machine from injecting to prevent low temperature related damage Use the Okay to Run output to change the machine state from Auto to Semi and inhibit injection to protect the hot runner manifold If the monitor zone is set to Alarm Only you could use the Okay to Run output to only reverse a
39. g a setpoint or many setpoints can be done in a similar fashion A simple text file named Setpoints txt is created and copied to the D G24 Network folder When the Setpoints txt file is read by the G24 the setpoints are sent to the controller and then the file is automatically deleted If an error is found in the file a Setpoints_Error txt file is created which is just the Setpoints txt file renamed Some operations may be completed in the event of an error Four five if deviation alarm settings are included setpoints may be changed using the Setpoints txt file Process temperature setpoint Manual percent setpoint Manual automatic mode status On Off Mode status Deviation Alarm if the Enable network access to the Deviation Setpoints button is selected The process temperature setpoint is set in Degrees F unless the Transfer file data in Degrees C button is selected as described above F process temperature setpoint in degrees F C process temperature setpoint in degrees C Manual percent setpoint 1 for manual mode 0 for automatic mode 1 for zone on 0 for zone off O letter DF Deviation alarm setpoint in degrees F if selected DC Deviation alarm setpoint in degrees C if selected To set a setpoint enter a line in the Setpoints txt file as shown by the example Tip 17 F 400 This will set the process temperature setpoint of zone Tip 17 to 400 F Note that the first entry of the line is the zone ID followed b
40. ith screen updates 5 Seconds Write the Values csv fileto USB papan minm LII rite the AltSetpoints txt Update the AllSetpoints txt file upon change in setpoint Transfer file data in Degrees Enable network access tothe Deviation Setpoints Exchange datain Truecsv file format 1111 Path Button Setup Application tostart G24 screen startup Launch anapplication 524 screen startup Task name of the application De gm E Tip Man Sprue Setup Network Access Press this button to access the screen shown Network Access Setup Network Command Path Click on this box to browse through the folders to find the folder that will be used to contain the network files The default location will normally be D G24 Network the example shows drive D 34 Network path for Values csv and AllSetpoints Files Click on this box to indicate where the Values csv and Allsetpoints txt files can be found The default location for these files is D G24 Network Update the Values csv file with screen updates If this box is checked the values in the Values csv file will be updated every 1 120 seconds based on the Seconds selection shown immediately to the right If this box is left empty the file will only be updated when an external computer requests that the file be generated Update the AllSetpoints txt file upon change in setpoint Check this box to alw
41. lb appearing brighter or dimmer followed by off on and failing the alarm uses the same principle the heater health is measured in Ohms and triggered with a 40 change from the baseline NOTE 1 Point out the automatic setup feature that will happen in the background for both features watt resistance alarms and the tuning results after 90 minutes of stable operation following the Are you making Good Parts and Yes response following the completion of the Wizard NOTE 2 If you are doing a training class or will not use this setup for production it is important to uncheck all the boxes to prevent the routine from occurring during the production run When complete press the arrow to the right button to go to Step 6 Step 6 Heat the Mold and notice the Sequence Start button if programmed You can skip this step and turn the system using the main screens if desired When desired press the arrow to the right button to go to Step 7 13 Step 7 e Save the Menu screen How do you know it is saved ANS The Menu appears on the list to the left Default mnu and Default 1 mnu will have the latest time date stamp these menus save your changes as they are made Only resaving the menu or checking the auto save feature will update the original menu Press the arrow to the right button to complete the Wizard process Main Wizard Screen e Startup Wizard initial screen How would you load and run a previous setup ANS
42. lve pins or create excessive pressure in the hot runner system by injecting when one or more of the zones is are cold prevent burning the material because the machine stopped for too long Refer to the Machine Interlocks section next for more information Configure the Remote Standby Group to change state based on a remote input Other general controller configuration Security levels 0 to go down a level 321 654 and 987 to go up one level at a time Default codes are listed programmable 21 E 22 5 A business of BARNES GROUP INC Machine Interlocks Water protect water and valve gate seals Use temperature monitoring feature spare control zone or Inhibit Okay to Run prevent cold valve gate movement or excessive pressure Dry contact output put machine in Semi prevent valve pin movement reverse conveyer robot in B position Standby avoid burning the material If the machine stops for too long then lower the temperature timer in machine or in controller using Material Protection Version Standard Synventive Audible Alarm control enclosure view ICM 2 Output female insert single latch auxiliary input output Note 2 Input Inhibit White Yellow Shipped from factory wired but not configured on the screen 22 E ynventive molding solutions business of BARNES GROUP INC Machine Interlock Water protect
43. mp Voltag Function Location Core Block PS inside Core Front Core PS 1 0305 see page 6 Core PS Test ICM see page 7 je Test Points Rating 80 8501 035 088 HUB PS Endosure 12 4 8501 036 Computer PS Enclosure Top Assy 24 4 VO Excitation Enclosure Top Assy 24 4 2 5A 8501 037 53 E G24 30A Output Module Diagram 12 DATES Pin Signal Pin Signal 1 Shield 1 14 OM A2 2 Shield2 15 3 Signal Gnd 16 5 T7 4 Signal Gnd_ 17 Control Disable G24 30A Output Module Schematic Typical 5 5Vdc 18 N Reset Heater i 6 5Vde 19 ICM A1 Wiring i 7 RS485 20 1 2 SC20 8 SC21 i 8 RS485 21_ 5 LINE HOT 5 gt gt 4 2 9 Synci 22 5Vdc RELAY FUSE 10 23 Signal Gnd 11 Sync2 24 Signal Gnd 12 OM A1 25 Drain 1 13 Sync3 26 2 lt 5 220 p22 LINE RET 1 gt gt 2 A RET OUT 28 DELTA MAINs Connect P20 to 21 Insert Fuse F21 CONNECTOR J2 WYE MAINs Connect P20 to P22 Remove Fuse F21 G24 30A Output Module PCB G24 30A Output p Module 5 LINE HOT lt 4 A HOT OUT 3 No connect lt 2 A RET lt 1 LINE RET CONNECTOR c gt 524 Reference Schematic P Esoso 746 54
44. multiple lines may be placed in the Menu txt command file Commands are executed in the order they appear in the file The following characters cannot be used as part of the menu file name passed within the command file 15 211 The commands that can be used in the Menu txt file Create Save a menu from the Active settings into Menus Activate Restore a menu from Menus to the Active settings Send Copy a menu from Network to Menus Get Copy a menu from Menus to Network Delete Delete a menu in Menus List Make a list of available menus located in Menus The Create and Activate commands can be used to remotely command the Operator Panel to save and restore menus without the user having to go to the Operator Panel screen to perform the operation The Create and Activate commands transfer information between the menus and the active settings that are currently in use on the controller Create This command creates or Save s a new OPERATOR PANEL menu The new menu is placed the Wenus directory If there is already a menu present with that same name then the existing menu will be renamed with a 1 attached to the end of the filename and the new one will be created The command has the form Create Sample mnu Activate This command activates or Restore s a menu The menu is restored from the Menus directory The command has the form Activate Sample mnu 38 The Send Get Delete and Li
45. n 32 6 Network Access English Only Section The G24 provides the ability to easily communicate over an Ethernet network using the Synventive Ethernet Network File Transfer Protocol Setpoints and menus can be sent from the network to the G24 Process values setpoints menus add status can be sent form the G24 to the network Files are exchanged through the Network folder typically located in the G24 directory The G24 Operator Panel screen detects when a command file has been received in the Network directory from the Ethernet network It opens it and performs the listed commands Upon performance the command file is deleted from the Network folder and will continue checking for the presence of new command files n 400 a Setpoint Table Alarm oF On ma Tip 4 gt Select Category Windows Information Program Screen Paths Job Information Exit to Windows Setup Network Access Screen Burn in Repair Setup Set Computer Limits Mold Menus The following functions are exposed for possible use with a touch screen operator panel that may not have an actual keyboard Diagnostics Display Taskbar z l Pdf Reports Display On Screen Keyboard EST The types of files within the file transfer protocol are Setpoints txt This file is placed in the Network folder by the external c
46. n for dry contact Timer in controller using Material Protection feature Choice B Send a signal every time the mold closes Ifthe signal does not repeat in the programmed time on screen then the controller goes to the standby temperature Controller requires a 24 volt input Loop voltage from pins 3 and 8 as shown for dry contact Standby is factory set to 220 degrees F 104 deg C Selectable standby set point by zone Molding Machine Floating Dry Contact Version 24 Standard 1 0 Yellow ICM 2 Input Control Allow inhibit White Yellow 24 Volt DC Supply Voltage Black Orange 1 Output Okay to Run Gray Brown Select Category Program Screen Paths Job Information Diagnostics 85 Pdf Reports Setup Limits Menus Windows Limits Various controller limits to manage the use of the controller Mold selection shown in yellow Startup Cool Down options configured in the Wizard Wizard Step 4 Group creation shortcut automatically created in the Wizard Wizard Step 1B Name zones select a range of zones to name or name one by one with the main drop down menu on the right side by pressing the upper right corner temperature value Wizard Step 1A Monitor zones automatically recognized and prompted in the Wizard Wizard Step 3 Calibration calibrate your controller with an accuracy of 0 2 0 1 degrees F C Food p
47. ng bit assignments Bit Assignment 0x0001 Ground Fault 0x0002 Zone Locked Weight 1 2 37 The following is an example of two lines the Values csv file Note that 1 is manual mode On has low alarm and a ground fault Tip 2 is in manual mode and has an active deviation low alarm 2048 128 2176 Tip 1 351 2 29 7 87 94 1 1 1 128 1 Tip 2 355 1 30 6 84 93 2 1 1 1 2176 0 Adding the setting Values 0 to the Setpoints txt file will cause the automatic updating to stop This may improve performance at the G24 Note that the setting of Values 0 or 1 is NOT SAVED when the G24 is powered down or exited and restarted The powerup default is to not create the file Adding Scale C to the Setpoints txt file causes both the AllSetpoints txt process temperature setpoints and the Values csv process values to be reported in degrees C Scale F causes those values to be in degrees F The power up default is degrees F The scale setting is NOT SAVED when the G24 is powered down or exited and restarted Menus Menus are manipulated with a text file named Menu txt that is created and placed into the D G24 Network folder When the Operator Panel detects a Menu txt file it opens the file and performs the operation as commanded and then deletes the Menu txt file If an error is found in the file that Menu txt file is renamed as Menu_Error txt file Some operations may still be completed in the event of an error Multiple commands and
48. oard If there is another pair of I O it will be located on the ICM on the next enclosure below Input LED on top Green when input signal is present otherwise off Output LED on bottom Orange green and red lit simultaneously when output relay is closed otherwise off Ribbon Cable Thermocouple Connector first 12 zones Thermocouple Connector next 12 zones Input Control Module ICM USB LED CPU LED Outputs LED Thermocouples LED USB Cable Connector Remote Input LED Remote Output LED Remote Input Output Connector The layout for the ICM board for those blocks that have enclosure doors that open to the left side of the controller For blocks with enclosure doors that open to the right side of the controller the second thermocouple connector on the board will be in a different location The second thermocouple board will be mounted on the forward side of the ICM board and forward in relationship to the first thermocouple board 60 11 Maintenance Cleaning For the exterior of the cabinet apply a high strength cleaner containing a grease cutter that is non abrasive and will not attack plastic Apply the cleaner to a soft cloth and gently wipe down the metal portions of the cabinet To clean the screen of the G24 use a soft moist cloth and gently wipe it down Do not spray liquids directly on the screen or into the cabinet Note No attempt should be made to clean the interior of the cabinet Shoul
49. omputer It is read amp then deleted by the Operator Panel It is used to change Setpoints and may instruct the Operator Panel to report active settings and process values 33 Setpoints_Error txt This file is used by the Operator Panel to save the errant file when an error is detected Setpoints txt file AllSetpoints txt This file is placed in the Network folder by the Operator Panel in response to a Setpoints txt file command It is used to report all active Setpoints Values csv This file is placed in the Network folder by the Operator Panel in response to a Setpoints txt file command It is used to report all active value and status information Menu txt This file is placed in the Network folder by the external computer It is read and then deleted by the Operator Panel It is used to instruct the Operator Panel to install the stated Menu MenusList txt This file is placed in the Network folder by the Operator Panel in response to a Menu txt file command It is used to report the contents of ALL menus in a memory folder Menu Error txt Used by the Operator Panel to save the errant file when an error is detected in a Menu txt file 400 7 8 Ez seren On Stanaby Boost Network Access Setup Network File Setup t D G24 Network Network command path D G24 Network Network path for Values csv and AllSetpoints fies Update the Values csv file w
50. ontroter Alarm P 4 Active Zone Alarms Clear Zone Alarm History Select Alarm Display Z e zone Alarm History Alarm History System Alarms and Status Clear System Alarm History ovenenp Aum Status of OK to Run eect Mone oo wp Systemis OKtoRut Configure Zone Alarms Spare 5 Monitor Top Active Zone Alarms section e Follow the Synventive Troubleshooting procedure next to discover the cause of the alarm e Probable fault locations Heater thermocouple issue Wiring in the mold Connector on top of the mold Connector to connector pin connection pin bent pushed back tool side Mold end of the cable connector Conductor s of the cable Enclosure end of the connector Connector to connector pin connection pin bent pushed back controller side Wiring inside the controller to the module The module or something else inside the controller The troubleshooting procedure systematically isolates the issue 8 0 SARS 15 2 Press the 2 button to display the Alarm Tutor screen Cover each alarm by asking the training group to describe the alarm and the potential problem without using the reference displayed to have better retention Alarm Tutor Zone Alarms AAI AS Deviation Low Alarm
51. rely clamped down and held in place If any are loose secure them before operating the controller Safety Symbols Used this Manual There are various symbols used with text and graphics to convey safety messages in this manual or in the product itself They follow the standard IEC 61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Description Notes Caution Attention refer to manual Caution High voltage is present inside possibility of electric shock Lockout Tag out the main power source Protective Conductor Terminal For safety purposes Alternating current Power ON Power OFF For non safety related Earth ground Terminal functions i e functional earth terminal Frame or Chassis Terminal 0 006 Hazard Alert symbols used to indicate the hazard alert message regardless of the hazard level The hazard level is conveyed by the use of the appropriate signal word Graphics within the triangle are used to further identify the specific hazard such as CAUTION THE G24 OPERATOR S MANUAL MUST BE CONSULTED ALL CASES WHERE THIS SYMBOL IS USED IN ORDER TO FIND OUT THE NATURE OF THE POTENTIAL HAZARDS AND ANY ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM CAUTION HIGH VOLTAGE NEVER REMOVE THE COVER TRY TO OPEN THE CABINET OR DISCONNECT CABLES WITHOUT TURNING OFF THE MAINS CIRCUIT BREAKER UNLESS YOU ARE PR
52. rocessing systems are typically calibrated every 6 months medical component manufacturers typically calibrate once a year Most systems are never checked or calibrated Ensuring the system is calibrated ensures good parts A typical calibration technician will check the controller accuracy with a thermocouple generator Fluke Omega and if the controller reads within 5 2 5 degrees F C the system is often certified as calibrated Use the Synventive software to change the calibration offset for ultimate accuracy Menus Save Restore mold setup Manage menus Diagnostics Mold Doctor Troubleshooting software Must stop the machine to use Mold Monitor Plastic leak alarm Heater failure prediction automatically set using the Wizard must wait for 90 minutes of production to accurately store a baseline Save the menu after storing the baseline Wizard Step 5 Mold Monitor Material Protection monitor the machine cycling put the controller into Standby if the machine stops for too long to prevent burning the material 27 Control Optimization e Control Tuning Optimal control is different for each application Normally 1 0 degree F or 0 5 degree C is optimized Each zone should be reviewed for optimal control by viewing the line graph example below If there is a suspected issue you may be able to improve the control with the Thermocouple or Tuning Issue procedure below Examples of tuning issues
53. st commands are used to manage the menus of several Operator Panel controllers on a shop floor from a production manager s computer This will allow the menus to be stored and archived in a common location The menus can be transferred from the archive through the Ethernet connection and downloaded to the Operator Panel prior to them being needed The Send command is used to copy it from the Network folder into the Menu folder When the job is complete then the Get command can be used to copy the menu from the Menus folder to the Network folder It can then be copied out with the use of the Ethernet connection back into the archive location The menu located in the OPERATOR PANEL Menus folder can be deleted with the use of the Delete command Send This command transfers a menu file from the Network folder to the Menus folder This command does not open or restore the menu It is only copied The mnu file does not contain any tool pictures The command has the form Send Sample mnu Get This command transfers a menu file from the Menus folder to the Network folder This command does not open or create the menu It is only copied The mnu file does not contain any tool pictures The command has the form Get Sample mnu Delete This command removes a menu file located in the Menus folder The command has the form Delete Sample mnu 39 7 G24 Reference Schematic VT tt senes A Update pg 12 13 15
54. tion of set point A business of BARNES GROUP No Alarms Monitoring zones in range Inputs normal Synventive contact closed when Okay to Run Machine Interlock Okay to Run prevent cold valve gate movement or excessive pressure Dry contact output 24 volt supply can be wired from pins 3 and 8 if needed Output to machine to change from Auto to Semi stopping the machine at the end of the cycle Prevent excessive pressure in the manifold if the system is not okay to run Output to machine to allow valve gate actuation Prevent valve pin movement when not ready moving the valve pin when cold can cause the pins to bend or break Output to reverse the conveyer Segregate potentially bad parts Output to put the robot in the B position Segregate potentially bad parts 1 91 Input Standby White Yellow ICM 2 Input Control Allow Inhibit White Yellow 24 Volt DC Supply Voltage Black Orange TCM 1 Output Okay to Run Gray Brown Version Standard 10 Controller Wiring Internal 25 E ynventive molding solutions business of BARNES GROUP INC Machine Interlock Standby avoid burning the material If the machine stops for too long then lower the temperature Timer in machine to close a contact to actuate Standby Choice A Controller requires 24 volt input Loop voltage from pins 3 and 8 as show
55. tware This function reroutes the thermocouple value from one zone to another to correct a miswired thermocouple e Output best used to provide the same power to both sides of a manifold heater if the thermocouple from one side is too close to the other causing a temperature imbalance This can also be used in the event of a lost thermocouple signal but it is preferred to use manual mode The remembered average percent output when the T C is lost by the controller automatically engages during production Use of manual mode or Copy output will clear the T C Open alarm e Find this Zone press the button and open the hardware to view the light identifying the module note the slot position on the screen matches the slot label in the control block Always use this feature prior to swapping a module to ensure the correct module is swapped CAUTION BE SURE MAIN POWER IS LOCKED OUT TAGGED WHEN SWAPPING ANY ELECTRICAL COMPONENTS View Line Voltage a quick diagnostic for overall controller troubleshooting PDF Reports e View Create Print Manage report creation e Ease the troubleshooting process by reviewing set point changes and alarms on the reports Windows e Set the date time e Screen burn in repair can be done while in production e Setup Network Access for data collection e Toggle to Windows by displaying the taskbar or Exit to Windows It is recommended to stop production when exiting to or working in Windows for any reaso
56. tware in use on the G24 this button should be pressed This box is normally left Application to start on G24 screen startup If the Launch an application on G24 screen startup box is checked press this box to browse and select the appropriate application that will start up with the G24 Task name of the application Enter the name that will be displayed in the application s screen title bar when the application is selected using the button in the lower right hand corner of the screen Phrase displayed on the button Enter the name of the application that will be displayed on a button on the screen if desired Place a button in the lower right hand corner of the screen Select this if it is desired to have a screen path to the other application Networking Protocol In the G24 folder is a folder named Network D G24 Network The Network folder should have the shared attribute set to shared when the operator panel is set up by the administrator Manipulation of setpoints and files is done by sending simple text only files of the type created by Windows Notepad Start each command at the first position of the line The text files used to command operations are selectable but normally placed within the D G24 Network directory The G24 controller detects that the files are now present opens them up and performs the operations as commanded The files are deleted when the command is complete 35 Setpoints and Values Changin
57. ually a strip of paper held over the vented areas of the cabinet will flutter when the fans are operational If one of the fans has failed the fan should be replaced immediately Check Temperature Calibration The maintenance schedule for recalibration of all temperature zones in the G24 system is dependent upon the nature of your molding process and the standards you are required to follow We recommend that your calibration be checked at least every two years by a qualified technician This can be readily accomplished by using the onboard Calibration software 61 12 Contact Information Literature manuals technical information and contact information can be found on our websites For sales and service support please contact us at North America Synventive Molding Solutions Inc 10 Centennial Drive Peabody MA 01960 USA Tel 1 978 750 8065 Fax 1 978 646 3600 email info synventive com www synventive com European Synventive Molding Solutions GmbH Heimrodstr 10 64625 Bensheim Germany Tel 49 0 6251 9332 0 Fax 49 0 6251 9332 90 email infohrde synventive com Asia 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 E Mail infohrcn synventive com 62
58. ure The purpose of this section is to determine if the control issue is related to an incorrect tuning value or a thermocouple with excessive noise typically referred to as an ungrounded T C CAUTION THE TUNING OVERRIDE SHOULD ONLY BE CHANGED IF YOU ARE HAVING ONE OF THE FOUR EXAMPLES OF TUNING ISSUES LISTED ABOVE NOTE THE ACTUAL TUNING SELECTED BY THE AUTOTUNE PRIOR TO MAKING ANY CHANGES TO EASILY REVERT BACK TO THAT VALUE Step 1 Start at a Known Point Change the tuning override to 10 for tips and 20 for Manifolds Observe the control Step 2A Results Tuning Issue 1 If the control stabilizes the auto tune picked poorly Selecting a tuning value other than Zero will disable the auto tune If this controller is dedicated to the mold this is your best option Each time the mold is powered the controller will simply use the tuning value you have now proven is correct 2 The control oscillates slowly up and down by equal amounts This indicates that the auto tune picked poorly This issue is usually limited to manifold transition or sprue zones Estimate the total oscillation in degrees F positive and negative i e set point of 400 high temperature of 403 and a low temperature of 397 equals total oscillation of 6 degrees F Make one adjustment for every 3 degrees F of total oscillation Oscillation of 3 degrees F would get a tuning value of 21 Oscillation of 6 degrees F would get a 22 Oscillation of 9 d
59. use Add USB Devices amp PE Pin Signal B 13 18 Cables needed USB 1 2 USBDM USB 2 to 3 DP USB Hub to Hub Connections to use the USB 3 Host 5 ed lowest USB Ports A 30584 USB Daisy Chain USB 5 USB Type A or B amp Connections to use the Pin Teal Wie Add USB next lowest 5 USB Ports Devices amp USB 1 0 Module 1 068 5V Red Connections to use the 2 USBDM White next lowest USB Ports 3 1058 Green G24 ICM Module 4 USB GND Black CONNECTOR 5 USB Shield Bare P6 USB 652053 Up to 2 Inputs 2 Outputs or 1 Output and Horn Used with Model Option Codes Group R U X Group T W G24 Aux I O 2 In 2 Out Diagram CHANGE WHO DATE AY See Sheet 1 Group Option Codes Wire 13 to Horn Horn Wire 1 Hl Brown Wire 13 Exin Black Ground Bar K Ground Bar 5 Orange Wie 1 oque qum mi m Fou Not Used Pin 6 Par aan ICM 1 COM P4 ICM 2 IN Mates to ICM 1 P2 ICM 2 COM AuxINCOM lt 1 _ Wire 8 Excitation 24Vde CON Relay Out Com E Weens PE Relay Out Snub Pn 6 Gray Pin 10 gt ICM 1 Out COM BS Inputs Energized 10 8 to 30 VAC Vdc COM pn 1 Wire 10 Not Energized 0 to 1 0 VAC Vde
60. ves and protective clothing when working around the feed throat purging the machine or clearing the gates of the mold Operators must be aware of the possibility and danger of hot resin and or gases spurting from gates machine nozzle and feed throat of the hopper Lockout Tag out Throughout this manual instructions are given to lockout tag out power sources Usually no instructions are given to turn the power source back ON This is assumed to have been covered by the instruction to perform any operation requiring the power source provided that all steps in the instructions prior to the power being applied have been completed If the power source must again be turned OFF the instruction to lockout tag out is repeated Housekeeping Clearly define areas for the controller to be positioned Provide clear access to the front and rear of the cabinet in case of an emergency Do not position the equipment so that it is difficult to operate the disconnecting device Check frequently for frayed or worn electrical cables located on the rear of the cabinet Replace any frayed or worn cable immediately once it is found Never place any materials on or near the controller cabinet that would block air flow near the cabinet ventilation ports Never clean the mold machine or hot runner controller while it is operating Never place any materials on top of the hot runner controller cabinet Make certain that all cable connectors on the rear of the cabinet are secu
61. water and valve gate seals Choice Use temperature monitoring feature spare control zone Programmable action alarm only standby or inhibit all zones off Machine interlock inhibit machine operation using Okay to Run output Temperature out of range water off lack of turbulent flow or too cold condensation Use a bayonet style thermocouple near the water out port wired to the hot runner cables Startup Wizard Tum Off aii of the zones in the controller when a Monitor Zone is detected Monitor Zone Alarm Delay Time sec 20 incide Monitor Zone Alarms in Ine OK to Run output 978 23 24 Bayonet style thermocouple example 9 9 Water Temperature Interlock EK ynventive molding solutions A business of BARNES GROUP INC Machine Interlock Water protect water and valve gate seals Choice Use Control Allow Inhibit input interlock External sensor shown with dry contact output when normal or out of range When sensor is in range or normal the contact is closed and allows the controller to operate Sensors available that monitor te re flow and or pressure SmartFlow Switching TRACER Flowmeter Out of range water off lack of turbulent flow or too cold condensation Set Lo Limit Flow Switch Point Enter Setup Mode see page 3 Press
62. xisting zone to be changed and then press the desired Zone Type name How does it determine if it is a Monitor zone ANS When the zones are turned the temperature will not rise because the output is not connected to a heater Press Accept Results when the names are correct Press the arrow to the right button to go to Step 2 Step 1B What happened in between Step 1 and Step 2 ANS The All Tip and Man Sprue group tabs were created Why did it combine the Man and Sprue zones together in a single group ANS For safety reasons To prevent a plastic explosion out the inlet if the Manifold is heated without the Sprue Inlet zone being heated It is necessary to give the pressure an outlet Why did it lock off the Spare zone s ANS The Spare zones are locked off to prevent an unwanted output and false alarms Why did it lock off the Monitor zone s ANS The Monitor zones are locked off to prevent an unwanted output and false alarms Step 2 What is the difference between Automatic and Manual mode ANS Automatic mode uses the thermocouples to monitor and control the desired setpoint Manual mode is used when a thermocouple is not available and a Output setpoint is used to control the zone output Why would you use Manual mode ANS Manual mode is used when a zone usually a tip does not have a thermocouple It can also be used when a thermocouple fails Related features R
63. y a space followed by the zone number and then followed by a colon It is very important to start the line in this manner and to spell the zone name correctly It may be easier to create an AllSetpoints txt file described later and modify it than to create one from scratch Any number of the setpoints may be included on the line if more than one setpoint per zone is to be changed For example Man 3 410 15 3 0 O 1 This will set the process temperature setpoint to 410 F the manual setpoint to 15 3 turn off manual mode turn on automatic mode and turn the zone on Any number of zones may be set in one file just use a new line for each zone In addition to setting setpoints the Setpoints txt file may include the following special instructions Setpoints 1 create a new AllSetpoints txt file Values 1 to create Values csv file automatically Values 0 to stop creating the Values csv file Scale C for degrees C Scale F for degrees F Adding the Setpoints 1 instruction causes the G24 to create an AllSetpoints txt file in the Network folder The AllSetpoints txt is a list of all of the four or five setpoints for each zone 36 The following is a few of the lines within AllSetpoints txt file Tip 1 F 410 15 0 M 0 7 0 M 0 4 F 415 17 0 M 0 The following is a couple of lines within AllSetpoints txt file with the optional setting to report the Deviation Setpoints

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