EWIKON motion CONTROL SD User manual

Controller for electric valve gate systems
with single linear servo drives
Operating manual
valid for item numbers:
68152.202
68152.204
68152.208
from software version 1.00.0
EWIKON 01/2022

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32022_01_Operating manual_motion CONTROL SD_EN.indd
Content
1. General information ................................................................................................................................................. 6
1.1 Information on this operating manual ........................................................................................................................ 6
1.2 Manufacturer .............................................................................................................................................................. 6
1.3 Formal information on this operating manual ............................................................................................................ 6
1.4 Conventions ............................................................................................................................................................... 7
1.4.1 Instructions and system responses ........................................................................................................................... 7
1.4.2 Enumerations ............................................................................................................................................................. 7
1.4.3 Abbreviations ............................................................................................................................................................. 7
2. Safety instructions .................................................................................................................................................. 8
2.1 Safety instructions and symbols used ....................................................................................................................... 8
2.1.1 Signalwordsforhazardclassication........................................................................................................................ 9
2.1.2 Explanation of pictograms ......................................................................................................................................... 9
2.2 Intended use ............................................................................................................................................................ 10
2.3 Improper use ............................................................................................................................................................ 10
2.4 Qualicationofsta󰀨 ................................................................................................................................................. 10
2.4.1 Requirementsonspecialisedsta󰀨........................................................................................................................... 10
2.5 Personal Protective Equipment (PPE) ..................................................................................................................... 10
2.5.1 Symbols of the personal protective equipment ........................................................................................................ 10
2.6 Hazards and safety measures in connection with hot runner systems .................................................................... 11
2.7 Electrical equipment ................................................................................................................................................ 13
2.8 Spare and wear parts, auxiliary material ................................................................................................................. 13
2.9 Limitation of liability .................................................................................................................................................. 13
2.10 Warranty terms ........................................................................................................................................................ 14
2.11 Standards and directives ......................................................................................................................................... 14
3. Technical Data ........................................................................................................................................................ 15
3.1 Mechanical data ....................................................................................................................................................... 15
3.1.1 Main dimensions / Dimensions of the motion CONTROL SD controller ................................................................ 15
3.2 Electrical data .......................................................................................................................................................... 15
3.2.1 Connections / Connector pin assignment ................................................................................................................ 15
3.3 Operating conditions ................................................................................................................................................ 15
3.4 Placing the controller ............................................................................................................................................... 16
4. Functional description of the motion CONTROL SD controller ............................................................................ 17
4.1 Required accessories (connection cables) .............................................................................................................. 17
4.2 Function ................................................................................................................................................................... 17
5. Operating instructions .......................................................................................................................................... 18

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5.1 Safety instructions ................................................................................................................................................... 18
5.2 Operating requirements ........................................................................................................................................... 19
5.2.1 Technical requirements ............................................................................................................................................ 19
6. Assembly ................................................................................................................................................................ 20
6.1 Safety instructions ................................................................................................................................................... 20
6.2 Checks before installation ........................................................................................................................................ 20
6.3 Installation ................................................................................................................................................................ 22
6.3.1 Connections and connector assignment of a 4-zone controller ............................................................................... 22
6.3.2 Connecting the motion CONTROL SD controller to the injection moulding machine ............................................. 23
6.3.3 Connecting the motion CONTROL SD controller to the mould .............................................................................. 25
6.4 Checks after assembly ............................................................................................................................................ 25
7. Start up ................................................................................................................................................................... 26
7.1 Basic settings and operation .................................................................................................................................... 26
7.2 Description of the menus ......................................................................................................................................... 27
7.2.1 Start page ................................................................................................................................................................ 27
7.2.2 Screen layout ........................................................................................................................................................... 28
7.2.3 Operation ................................................................................................................................................................. 30
7.2.3.1 Manual operation ..................................................................................................................................................... 30
7.2.3.2 Automatic operation ................................................................................................................................................. 31
7.2.3.3 Error messages of the servo controller .................................................................................................................... 32
7.2.4 Congurationofdrives............................................................................................................................................. 33
7.2.4.1 General (basic settings) ........................................................................................................................................... 33
7.2.4.2 Motion(Motionprolesetting) ................................................................................................................................. 34
7.2.4.3 Monitoring ................................................................................................................................................................ 35
7.2.4.4 Options (Optional settings) ...................................................................................................................................... 36
7.2.4.5 Extended (Extended settings) .................................................................................................................................. 36
7.2.5 Setup System & Device ........................................................................................................................................... 37
7.2.5.1 General .................................................................................................................................................................... 37
7.2.5.2 Display & View ......................................................................................................................................................... 38
7.2.5.3 Network .................................................................................................................................................................... 39
7.2.5.4 Analog IN ................................................................................................................................................................. 39
7.2.5.5 OPC UA Id ............................................................................................................................................................... 40
7.2.6 Diagnosis and troubleshooting ................................................................................................................................ 41
7.2.6.1 Alarms ...................................................................................................................................................................... 41
7.2.6.2 Alarm history ............................................................................................................................................................ 41
7.2.6.3 I/O Test .................................................................................................................................................................... 42
7.2.6.4 System Diagnostics Manager (SDM) ....................................................................................................................... 42
7.2.7 File management ..................................................................................................................................................... 43

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7.2.7.1 Internal ..................................................................................................................................................................... 43
7.2.7.2 External USB ........................................................................................................................................................... 43
7.2.7.3 Report ...................................................................................................................................................................... 44
7.3 Help in case of malfunctions .................................................................................................................................... 45
7.3.1 Troubleshooting ....................................................................................................................................................... 45
7.3.2 Spare parts list ......................................................................................................................................................... 45
7.3.3 EWIKON service departments ................................................................................................................................. 45
8. Quick Start Guide .................................................................................................................................................. 46
9. Service and maintenance ...................................................................................................................................... 47
9.1 Maintenance instructions ......................................................................................................................................... 47
9.2 Safety instructions for maintenance ......................................................................................................................... 47
9.3 Maintenance work .................................................................................................................................................... 48
9.3.1 Changingthelter.................................................................................................................................................... 48
9.3.2 Cleaning the motion CONTROL SD controller ....................................................................................................... 48
9.3.3 Checking fan or fan grille ......................................................................................................................................... 48
9.4 Service and repair instructions ................................................................................................................................ 48
10. Decommissioning .................................................................................................................................................. 49
10.1 Returning the motion CONTROL SD controller ...................................................................................................... 49
10.2 Safety instructions for dismantling ........................................................................................................................... 49
10.3 Disposal instructions ................................................................................................................................................ 49
EC - Declaration of Conformity ........................................................................................................................................... 51

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1. General information
1.1 Information on this operating manual
Theseoperatingmanualhasbeenpreparedinaccordancewithdirective2006/42/EC.Itenablesthesafeande󰀩cient
operation of motion CONTROL SD controllers.
1.2 Manufacturer
EWIKON Heißkanalsysteme GmbH
Siegener Straße 35
35066 Frankenberg
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.ewikon.com
1.3 Formal information on this operating manual
Person in charge of documentation: Horst Balzer
Version: 1.0, date: 23/06/2022
Language: German (original operating manual); English
© Copyright, 2022
All rights reserved. Full or partial reproduction subject to prior written
approval by EWIKON Heißkanalsysteme GmbH
NOTE!
Improper operation of the device may result in severe personal injury and considerable material damage!
You must carefully read this operating manual and familiarise yourself with the safety installations before
installing, commissioning or maintaining the device. Do not operate the device without having received
appropriate training.

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1.4 Conventions
1.4.1 Instructions and system responses
Operating steps that have to be carried out by the operator are displayed as a numbered list.
The sequence of the steps has to be adhered to.
Example:
1. Operating step 1
2. Operating step 2
1.4.2 Enumerations
Enumerations without mandatory sequence are displayed as a list with bullet points.
Example:
• Point 1
• Point 2
1.4.3 Abbreviations
The following terms and abbreviations are used in the operating manual:
Abbreviation Meaning
PPE Personal protective equipment
PE Protective earth conductor
EU European Union
Chart 1: Terms and abbreviations

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2. Safety instructions
The motion CONTROL SD controller complies with the Low Voltage Directive 2014/35/EU and the EMC Directive
2014/30/EU and has been designed, manufactured and tested for safety in accordance with the currently applicable safety
regulations and laws and the state of the art. If the motion CONTROL SDcontrollerisusedinamannernotspeciedby
EWIKON, the function of the protective devices of the device may be impaired.
The motion CONTROL SD controller is delivered in perfect technical condition.
However, hazards can arise from motion CONTROL SD controllers if they are:
• operated by personnel who have not been properly trained.
• used improperly or not as intended.
• not in perfect condition from a safety point of view.
2.1 Safety instructions and symbols used
The safety instructions are introduced with signal words and are marked by symbols. They draw attention to dangerous
situations that may arise during installation, operation and maintenance work. Safety instructions must be observed to avoid
accidents, personal injury and damage to material.
Warnings
• protect against possible personal injury and damage to material if observed.
• classify the extent of the hazard by means of the signal word.
• indicate the danger of personal injury by means of the hazard sign.
• indicate the type and source of the hazard.
• indicate the risk and the possible consequences.
• indicate measures to avoid hazards and prohibit certain types of behaviour.
WARNING! = Signal word
Source of hazard
Possible consequences, if ignored
• Measures / prohibitions
The hazard sign marks warnings which warn against personal injuries.
Source of hazard
The source of hazard indicates the cause of hazard.
Possible consequences, if ignored
If the warnings are ignored, possible consequences will be e. g. crushing, burnings or other severe injuries.
Measures / Prohibitions
“Measures / Prohibitions” lists actions that are to be carried out to prevent a hazard (e. g. stop a drive) or that are
prohibited in order to prevent a hazard.

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2.1.1 Signal words for hazard classication
HAZARD
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING!
Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, will result in minor injury or material damage.
NOTE
Indicates useful additional information and tips to promote trouble-free operation and to prevent material
damage.
2.1.2 Explanation of pictograms
Read operating manual Caution! Risk of electrocution
Caution! Hot surface Caution! Oxidising agents
Caution! Suspended load Caution! Risk of hand injuries / crushing
Caution! Explosive atmosphere Caution! Risk of hand and cut injuries
Caution! Systems under pressure Caution!Movingforklifttra󰀩chazard

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2.2 Intended use
EWIKON controllers are designed exclusively for the intended use described here.
Any other use contrary to the intended use is excluded and may lead to personal injury and damage to material. In this case,
the warranty expires.
The motion CONTROL SD controller is to be used exclusively for controlling the valve pin movement of EWIKON valve gate
hot and cold runner systems installed in a closed injection mould.
Intended use requires that all notes and information in these operating manual are read, understood and observed.
To ensure safe operation of the motion CONTROL SDcontroller,thespeciedmaintenanceandinspectionintervalsmust
be observed.
Use of the motion CONTROL SD controller
Only use the motion CONTROL SD controller for its intended purpose and in perfect condition in terms of
safety! This is the only way to ensure the operational safety of the motion CONTROL SD controller.
2.3 Improper use
Anyusenotspeciedunderorgoingbeyondtheintendeduseisconsideredimproperuse.
2.4 Qualication of sta󰀨
Thesta󰀨musthavetheappropriatequalicationsforassembly,maintenanceandrepair.
Anylackofknowledgeonthepartofthesta󰀨mustbeeliminatedthroughtrainingandinstruction.
2.4.1 Requirements on specialised sta󰀨
Improper use of EWIKON controllers can lead to personal injury and damage to material. All work must be carried out by
specialisedsta󰀨only.
Onlytrainedspecialisedsta󰀨isallowedtoconnectandoperateEWIKONcontrollers.Specialisedsta󰀨hastechnicaltraining,
proven knowledge and experience in handling e.g. injection moulding equipment or electrical systems, as well as knowledge
of the relevant safety regulations and is able to independently recognise possible dangers and avoid them by taking suitable
protective measures.
2.5 Personal Protective Equipment (PPE)
Wear the necessary protective equipment when working on or near the machine. Special instructions for personal protective
equipment in the working area must be observed.
2.5.1 Symbols of the personal protective equipment
Always wear the following when carrying out any work:
Protective clothes:Toprotectyourbodyweartight-ttingclotheswithlowresistancetotearing,without
protruding parts and with long sleeves and long trousers. Do not wear rings, chains or any other jewelry.
Safety shoes: To protect yourself against electric shocks, melt splashes, heavy, falling objects and slips
and falls on slippery surfaces.