MAXIMATOR RM350 Operating instructions

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 1 of 18
INSTALLATION &
COMMISSIONING
INSTRUCTIONS
RM350
Contents
Safety .............................................................................................................................................................................................2
Warranty Registration Form ..........................................................................................................................................................3
Installing the Equipment................................................................................................................................................................4
Installation and Location............................................................................................................................................................ 4
General Information ..................................................................................................................................................................4
Location of Connections ............................................................................................................................................................5
Power Connections ....................................................................................................................................................................7
Interface Signal Connections .........................................................................................................................................................8
Injection Moulding Machine Interface....................................................................................................................................... 8
Mould Actuator Interface ........................................................................................................................................................11
Euromap 62 Adaptor................................................................................................................................................................ 15
Commissioning.............................................................................................................................................................................18

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 2 of 18
Safety
Please read the following information carefully before installing and using the equipment.
Compressed air and gases can be EXTREMELY dangerous and MUST be treated with extreme
care. This equipment works at pressures up to 620 Bar (8990 psi) and uses single and 3 phase
electrical power (certain models).
REMEMBER: Nitrogen gas is an asphixiant. Never breathe in gas escaping from the system. Nitrogen
gas is not poisonous, but can overcome a person in a confined space. Always stay alert when venting
Nitrogen gas.
REMEMBER: don’t be fooled by the size of the high-pressure receiver. A 50-litre receiver charged to
350 Bar contains the equivalent of 17500 liters of gas at atmospheric pressure.
REMEMBER: unlike hydraulic oil, gas is compressible, and will continue to expand until the pressures
inside and outside the system equalise.
NEVER commence any maintenance or servicing work on the equipment without ensuring that the
system is depressurised.
NEVER adjust a pipefitting that is under pressure.
NEVER adjust a safety valve to achieve a lifting pressure higher than that set at the Maximator factory.
Asafety valve is provided to prevent over pressurisation of the system and overloading of the
compressor. Tampering with a safety valve can cause serious damage or injury.
NEVER run the equipment without the guards it was supplied with.
NEVER re-use damaged fittings, especially if they rely on threads for security (i.e. pipe fittings, nuts,
bolts, etc).
NEVER attempt to straighten badly bent pipes
NEVER allow any part of your body or any person to be in front of an opening that is venting gas.
Particles from inside the system can become embedded in the skin and cause serious injury or death.
ALWAYS take care when opening valves or venting the system, and open the valve
slowly. ALWAYS isolate the electric power supply before commencing work on the system.
ALWAYS entrust electrical work to a qualified electrician.
ALWAYS comply with local, regional and national legislation.
REMEMBER:
COMPRESSED GAS AND ELECTRICITY CAN KILL.
TREAT THEM WITH RESPECT.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 3 of 18
Warranty Registration Form
In order that we can improve our service to you, please complete the warranty
registration form below and return:
By post to Maximator UK Ltd
Unit 9 King Street Industrial Estate
Middlewich,
Cheshire,
CW10 9LF
United Kingdom
By email to: [email protected]
Customer:
Factory address:
Agent:
Equipment model:
Serial number:
Equipment received on:
Installing company:
Installing engineer:
Installation date:
Commissioning company:
Commissioning engineer:
Commissioning date:

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 4 of 18
Installing the Equipment
Installation and Location
The gas controller MUST be installed indoors.
Never operate, store or transport the gas controller where there may be:
Rainfall or other falling water.

Excessive dust.

Corrosive vapours or substances.

Lying water.

A risk of the temperature falling below 0ºc (32ºF).

Where the ground is slopping or uneven ground.
Do not cover the gas controller during operation, or obstruct the flow of any cooling air in any way.
General Information
Photographs shown within this manual section are for illustration purposes only. All hardware and
fabrications are subject to change without prior notification.
Before operating or carrying out maintenance on the equipment, operators and maintenance
personnel MUST be familiar with the layout, connections and operation of the equipment.


Safety valves MUST NOT be tampered with as they are factory set and could cause irreparable
damage to equipment and cause serious injury.


All equipment or pipe work installed MUST be rated correctly for the operation pressure of the gas
controller.

Even if you are only using the controller with one molding machine, both interface plugs must
still be used, and the E-stop connections must both be either connected or linked out. The
controller will not run unless E-Stop signals are present in both interfaces.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 5 of 18
Location of Connections
RM350 Without booster
DESCRIPTION
PORT SIZE
1
Isolator 25 Amp
N/A
2
Mains Power Connection 110-220 V ac 50/60 HZ
N/A
3
32 Way IMM Interface Plugs
N/A
4
Alarm/Beacon
N/A
5
Inlet Gas Manifold
G1/4
6
GCM 1-4 Outlet Gas Manifold
G1/4
7
Emergency Stop Button
N/A
8
Reset Button/Lamp
N/A
9
Auto Button/Lamp
N/A
1
2
3
4
5
6
8
7
9

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 6 of 18
RM350 With booster
DESCRIPTION
PORT SIZE
1
HP Gas Receiver Pressure Gauge
N/A
2
Injection Moulding Machine Interface Socket (2 IMM`s Max)
N/A
3
Power Connection 110-220 V ac 50/60 HZ (Model Shown) or 25mm
N/A
Cable Gland for 3 Phase Systems
4
HP Receiver Vent Valve
N/A
5
GCM Outlet Bulkhead (4 Maximum)
¼” BSP (ISO)
6
Air inlet Bulkhead (If Fitted)
½”BSP (ISO)
7
N2 Gas Inlet Bulkhead
¼” BSP (ISO)
8
Emergency Stop Button
N/A
9
Operator Interface
N/A
10
Reset Push Button/Lamp
N/A
11
Auto Push Button/Lamp
N/A
1
2
3
4
5
6
7
8
10
11
9

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 7 of 18
Power Connections
The gas controllers are set to operate at the correct voltage in the country of use. All mains power
connections MUST have an earth fitted. The earth not only helps to ensure electrical safety, but can
increase the stability of some of the analogue signals in the control system.
Single Phase Power Connections
The single phase units are supplied with a power cable that requires terminating at the factory power
source. The connections are as follows:
Brown or Red: Live
Blue or Black: Neutral
Green/Yellow: Earth
Three Phase Power Connections
NOTE: Customer terminations are marked as follows.
L1: Phase 1 Terminal
L2: Phase 2 Terminal
L3: Phase 3 Terminal
N: Neutral terminal (If Required)
PE: Power Earth Terminal MUST Be Fitted
All electrical connections must be carried out by a suitably qualified electrician in
accordance with local, regional and national legislation.
PE
L3
L2
L1
N

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 8 of 18
Interface Signal Connections
Injection Moulding Machine Interface
Mould Closed
This signal is used for safety, and to allow manual and automatic cleaning between cycles. The signal
must be in the CLOSED state for a gas cycle to run.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Clamp closed; micro switch.
Interlock Signal
This signal is used for safety and the controller will not run a cycle unless this signal is present
(normally closed)
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Safety guard, Purge guard.
Gas Start Signal
This is a DIGITAL START SIGNAL provided by the moulding machine normally via a
relay. The signal is required from the moulding machine at the start of polymer injection.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Micro switch; Polymer injection

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 9 of 18
External E-Stop
This is an emergency stop control signal, when the signal is wired into the emergency stop circuit on
the IMM (This MUST volt free) and the e-stop button is pressed on the IMM the GAS controller will stop
immediately and show an E-Stop alarm.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
E-stop button
NOTE: Even if you are only using the controller with one molding machine, both interface
plugs must still be used, and the E-stop connections must both be either connected or linked
out. The controller will not run unless E-Stop signals are present in both interfaces.
IMM Reset Signal
This signal can be used to reset all the hydraulic cores (on units with hydraulic power pack or signal
option pack) using a signal from the moulding machine. This signal is OPTIONAL. If it is not used, the
controller will use the timers in the HPP screen to reset the cores at the end of the cycle.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Gas Unit In Cycle
This is an output signal from the gas controller that may be used to indicate when a gas cycle is
running.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
open contacts of R3 on the PCB. The
contacts are rated up to 2A/250 V ac.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 10 of 18
Gas Unit Not In Cycle
This is an output signal from the gas controller that may be used to indicate when the gas cycles are
not running.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
closed contacts of R3 on the PCB. The
contacts are rated up to 2A/250 V ac.
Gas Unit Ready
This is an output signal from the gas controller that may be used to indicate when the controller is
ready to cycle. The Controller will then start a cycle when the next gas start signal is received.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
open contacts of R2 on the PCB. The
contacts are rated up to 2A/250 V ac.
Gas Unit Emergency Stop
This is an output signal from the gas controller that may be used to indicate when the gas controller
emergency stop button has been pressed.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
open contacts of R5 on the PCB. The
contacts are rated up to 2A/250 V ac.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 11 of 18
Hydraulic Power Pack
This is an output signal from the gas controller that may be used to indicate when the hydraulic power
pack is running.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
open contacts of R6 on the PCB. The
contacts are rated up to 2A/250 V ac.
Suggested Connections IMM:
Auxiliary contact on hydraulic
power pack.
Mould Actuator Interface
Core In Signals
Output signals (24 V dc), to move the hydraulic cores to the in position.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 12 of 18
Core Out Signals
Output signals (24 V dc), to move the hydraulic cores to the out position.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 13 of 18
Overload
This signal is used for safety and the controller will show an overload alarm in the status page if the
overload trips out on the hydraulic power pack.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Overload auxiliary contact
Oil Temperature
This signal is used for safety and the controller will show an oil temperature alarm in the status page if
the oil temperature goes above its set level..
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Temperature switch
Oil Level
This signal is used for safety and the controller will show an oil level alarm in the status page if the oil
level falls below its minimum set point.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Level switch
Pressure Bypass
This signal is used to actuate the pressure bypass solenoid on the external hydraulic power pack.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 14 of 18
Pump Run
This signal is used to turn on the contactor for the hydraulic power pack.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Contactor coil (24 V dc)
Hydraulic Power Pack E-Stop
This is an emergency stop control signal, when the signal is wired into the emergency stop circuit on
the gas controller (This MUST volt free) and the e-stop button is pressed on the hydraulic power pack
the gas controller will stop immediately and show an E-Stop alarm
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Temperature switch

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 15 of 18
Euromap 62 Adaptor
A Euromap 62 interface is possible and is achieved with an adaptor which is added to the inside of the
controller. The Euromap adaptor can be added to any controller. If a Euromap adaptor is fitted it can be
removed and operation will then be according to the standard interface described in the previous pages.
Note that the Euromap interface is not fully implemented. Please see the following notes for details:
1. The Euromap interface has separate signals for front and rear guards. These are combined
into one "safety" signal by the adaptor. Only if both guards are closed will the safety signal be
received by the controller. Users should note that there will be no indication on the controller if
only one of the guards is closed.
2. The "Mould open, ready to close", "IMM fail" and "IMM auto" signals in the Euromap interface
are not implemented.
3. The "enable mould open" and "enable mould close" are partially implemented. These signals
(pins 25 and 26) will be high when the controller is not in a cycle, and low when it is running a
cycle.
4. The "reject" and "controller fail" signals in the Euromap interface are not implemented.
The signals for the Euromap adaptor are shown below.
Mould Closed
This signal is used for safety, and to allow manual and automatic cleaning between cycles. The signal
must be in the CLOSED state for a gas cycle to run.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Clamp closed; micro switch.
Guards Closed
This signal is used for safety and the controller will not run a cycle unless this signal is present
(normally closed)
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Safety guard, Purge guard.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 16 of 18
Gas Start Signal
This is a DIGITAL START SIGNAL provided by the moulding machine normally via a
relay. The signal is required from the moulding machine at the start of polymer injection.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
Micro switch; Polymer injection
Moulding Machine E-Stop
This is an emergency stop control signal, when the signal is wired into the emergency stop circuit on
the IMM (This MUST volt free) and the e-stop button is pressed on the IMM the GAS controller will stop
immediately and show an E-Stop alarm.
GAS ControllerInjection Moulding Machine
NOTE:
All connections must be volt free at
IMM.
Suggested Connections IMM:
E-stop button
Gas Unit Emergency Stop
This is an output signal from the gas controller that may be used to indicate when the gas controller
emergency stop button has been pressed.
GAS ControllerInjection Moulding Machine
NOTE:
This connection is through the normally
open contacts of R5 on the PCB. The
contacts are rated up to 2A/250 V ac.

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 17 of 18
Enable Mould Open
When the controller is not running through a cycle, this signal will be high; the moulding machine may
open the mould.
GAS ControllerInjection Moulding Machine
NOTE:
.
Enable Mould Closed
When the controller is in automatic and ready to cycle, but not running a gas cycle, this signal will be
high; the moulding machine may open the mould.
GAS ControllerInjection Moulding Machine
NOTE:
.
ENABLE MOULD OPEN
ENABLE MOULD CLOSED

RM350
INSTALLATION AND COMMISSIONING
RM350 GAS CONTROLLERS MAY 16 18 of 18
Commissioning
Once the equipment is unpacked, assembled and all connections are made, it is ready for
commissioning. Since the equipment is fully pre-tested at the factory, commissioning is a simple
process.
To commission the equipment, follow these steps:
Ensure that the unit is unpacked, assembled and checked in accordance with the instructions in this
manual
Read the operating instructions
Ensure that the connections (Hydraulic, Electrical, Air, Gas, GCM) have been made in accordance with
the instructions in this manual.
1. Connect the moulding machine interface as stated in the previous section
2. Pull out the Emergency stop button and press the reset button (refer to operating
instructions)
3. Turn on the gas and air supply (air supply if booster fitted only)
4. Set a booster set pressure greater than the process pressure required, if a booster is
fitted, or ensure that the inlet gas pressure is higher than the required pressure if no
booster is fitted
5. On units fitted with or connected to a hydraulic power pack, ensure that the direction of
rotation is correct. Rectify if not.
6. Check all pipe fittings and pressure connections for leaks.
7. Fit all hydraulic connections (quick connects supplied)
8. Enter required process parameters. (Refer to operating instructions)
9. Select automatic mode (see operating instructions)
10. Select the appropriate interface
11. Operate the moulding machine and the controller will run accordingly
12. During operation, check all HP fittings for leaks.