RJG 211M18 User manual

PRODUCT MANUALPRODUCT MANUAL
Training and Technology for Injection Molding
P L W
S
211M18

PRINT DATE 01.27.2022
REVISION NO. 0

Product Manual | Piezoelectric Load Washer Sensor 211M18 i
PRODUCT MANUAL
P L W
S
211M18
INTRODUCTION
DISCLAIMER V
PRIVACY V
ALERTS V
PRODUCT DESCRIPTION
APPLICATIONS 1
EJECTOR SLEEVES AND CORES 1
SINGLECHANNEL 1
MULTICHANNEL 1
OPERATION 2
LOAD WASHER SENSORS 2
PIEZOELECTRIC SENSORS 2
DIMENSIONS 3
SENSOR 3
CABLE LENGTHS 3

Piezoelectric Load Washer Sensor 211M18 | Product Manual
ii
INSTALLATION
INSTALLATION OVERVIEW 5
INSTALLATION SPECIFICATIONS 6
SENSOR POCKET 7
EJECTOR SLEEVE POCKET 7
EJECTOR SLEEVE COUNTERBORE OPTIONAL 7
CABLE CHANNEL 8
ALTERNATE INSTALLATION OVERVIEW 9
ALTERNATE INSTALLATION SPECIFICATIONS 10
SENSOR AND SPACER POCKET 11
SPACER 11
EJECTOR SLEEVE AND CORE PIN POCKETS 11
CABLE CHANNEL 12
SENSOR CABLE RETENTION 13
SENSOR INSTALLATION CHECK 15
PREASSEMBLY CHECKS 15
POSTASSEMBLY CHECK 15
PRODUCT MANUAL
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211M18

Product Manual | Piezoelectric Load Washer Sensor 211M18 iii
MAINTENANCE
CLEANING & DRIFT 17
REGULAR CLEANING 17
DRIFT 17
TESTING & CALIBRATION 17
SENSOR TESTING 17
WARRANTY 18
RJG, INC. STANDARD THREEYEAR WARRANTY 18
PRODUCT DISCLAIMER 18
TROUBLESHOOTING
INSTALLATION ERRORS 19
LOADING SURFACE ISSUES 19
CABLE AND CASE ISSUES 20
CABLES 20
SENSOR ADAPTER CASES 20
COMMON ERRORS 21
SLOW SENSOR DRIFT READING 22
FAST SENSOR DRIFT/INVALID READING 23
SENSOR DOES NOT COMMUNICATE WITH EDART 24
CUSTOMER SUPPORT 25
PRODUCT MANUAL
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211M18

Piezoelectric Load Washer Sensor 211M18 | Product Manual
iv
RELATED PRODUCTS
COMPATIBLE PRODUCTS 27
SINGLECHANNEL LYNX LOAD WASHER SENSOR CABLE CLW003C10F27
MULTICHANNEL LYNX LOAD WASHER SENSOR CABLE
CLW003C10A 27
LYNX CABLES CELX5 27
LYNX SINGLECHANNEL MOLD MOUNT SENSOR ADAPTER LP/LX1M 28
LYNX SINGLECHANNEL SURFACE MOUNT SENSOR ADAPTER PZ/LX1S28
PZ4 & PZ/LX4FS 28
PZ8 & PZ/LX8FS 28
PRODUCT MANUAL
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211M18

Product Manual | Piezoelectric Load Washer Sensor 211M18 v
INTRODUCTION
Read, understand, and comply with all
following instructions. This guide must be
kept available for reference at all times.
DISCLAIMER
Inasmuch as RJG, Inc. has no control
over the use to which others may put
this material, it does not guarantee that
the same results as those described
herein will be obtained. Nor does RJG,
Inc. guarantee the effectiveness or safety
of any possible or suggested design
for articles of manufacture as illustrated
herein by any photographs, technical
drawings, and the like. Each user of the
material or design or both should make
his own tests to determine the suitability
of the material or any material for the
design as well as the suitability of the
material, process, and/or design for his
own particular use. Statements concerning
possible or suggested uses of the material
or designs described herein are not to be
construed as constituting a license under
any RJG, Inc. patent covering such use
or as recommendations for use of such
material or designs in the infringement of
any patent.
PRIVACY
Designed and developed by RJG, Inc.
Manual design, format and structure
copyright 2022 RJG, Inc. content
documentation copyright 2022 RJG, Inc. All
rights reserved. Material contained herein
may not be copied by hand, mechanical, or
electronic means, either whole or in part,
without the express written consent of RJG,
Inc. Permission will normally be granted for
use in conjunction with inter‑company use
not in conflict with RJG’s best interests.
ALERTS
The following three alert types are used
as needed to further clarify or highlight
information presented in the manual:
DEFINITIONA definition or clarification of a
term or terms used in the text.
NOTESLA note provides additional
information about a discussion
topic.
CAUTIONaA caution is used to make the
operator aware of conditions that
can cause damage to equipment
and/or injury to personnel.

Piezoelectric Load Washer Sensor 211M18 | Product Manual
vi
NOTES

Product Manual | Piezoelectric Load Washer Sensor 211M18 1
PRODUCT DESCRIPTION
The 211M18 load washer sensor from
RJG, Inc. is a digital piezoelectric sensor
that measures cavity pressure on ejector
sleeves. The core pin extends through the
load washer so that only pressure from the
ejector sleeve is monitored.
The piezoelectric load washer sensor is
designed for use with the RJG eDART® or
CoPilot® process control and monitoring
systems. The 211M18 boasts a 5,000 lb.
(22,24 kN) capacity and a sensitivity rating
of 4,047 pC/kN.
APPLICATIONS
EJECTOR SLEEVES AND CORES
Load washers enable the use of cavity
pressure sensors in ejector sleeve and
core applications. The load washer
sensor is suitable for injection molding
applications in which the following
conditions are met:
• Applied pressure is high enough to
prevent poor sensor resolution, but low
enough to prevent sensor damage.
• Sensor will be kept below 400 °F (204
°C) in the mold; sensor electronics will be
kept below 140 °F (60 °C).
• The ejector sleeve will contact at least
80% of the sensor loading surface.
SINGLECHANNEL
The 211M18 can be utilized in
single‑channel applications in conjunction
with the Lynx™ Mold‑Mount Piezoelectric
Sensor Adapter
LP/LX1‑M and the eDART system.
MULTICHANNEL
The 211M18 can be utilized in multi‑channel
applications which enable either four or
eight sensors to be connected outside
the mold with a single cable. The Lynx
Four‑Channel Piezoelectric Sensor
Connector and Adapter—PZ‑4 and PZ/
LX4F‑S‑ID—allow up to four sensor
connections, while the Lynx Eight‑Channel
Piezoelectric Sensor Connector and
Adapter—PZ‑8 and PZ/LX8F‑S‑ID—allow up
to eight sensor connections to the eDART
system.

Piezoelectric Load Washer Sensor 211M18 | Product Manual
2
OPERATION
LOAD WASHER SENSORS
The piezoelectric load washer sensor is
placed in the ejector retainer plate behind
the ejector sleeve. The ejector sleeve
core pin extends through the sensor and
sleeve. When the mold clamps and plastic
is injected, pressure is transferred from
the ejector sleeve onto the load washer.
The load washer measures the force, and
calculates the pressure based on the scale.
The accuracy of the sensor is dependent
upon the scale. The sensor is programmed
for 125 or 500 lb. as full scale, depending
upon sensor ordered. The eDART
computes a scale factor based on the
full scale value while pressure is being
applied.
PIEZOELECTRIC SENSORS
Piezoelectric sensors use quartz crystals
to measure the deformation, or change in
resistance of the force over the sensor. The
measurement is carried through the sensor
cable to a sensor adapter mounted on the
outside of the mold.
Piezoelectric quartz crystals contain
balanced negative and positive electrical
charges which are not symmetrically
arranged. When force is applied to the
piezoelectric crystal, the positive and
negative atoms are deformed, pushing
some of the atoms closer or further apart
and causing electrical charges to occur.
The sensor adapter is connected to
the RJG, Inc. eDART or CoPilot system,
which records and displays the sensor’s
measurement for operator aid in process
monitoring and control.
OUTPUT
PRESSURE
PRESSURE
PIEZOELECTRIC SENSOR OPERATING PRINCIPLE
EXCITATION

Product Manual | Piezoelectric Load Washer Sensor 211M18 3
DIMENSIONS
SENSOR
CLW003C10F ORDERING LENGTH
CLW003C10A ORDERING LENGTH
CABLE LENGTHS
Length must be longer than needed to
facilitate safe installation and removal of
connector from tool to prevent tension on
the lead wire; generally, 2–3” (50–75mm)
of slack is sufficient. Use good sense to
determine the appropriate cable length
required for each application. Length
specified at time of order.
COMPATIBLE CABLES
Single-Channel C-LW003C10-F
Multi-Channel C-LW003C10-A

Piezoelectric Load Washer Sensor 211M18 | Product Manual
4
NOTES

Product Manual | Piezoelectric Load Washer Sensor 211M18 5
INSTALLATION
INSTALLATION OVERVIEW
A channel is machined into the mold for the
sensor cable and sensor head. The sensor
head is placed under the ejector sleeve in
the mold ejector retainer plate. An ejector
sleeve core pin extends through the sensor
head and ejector sleeve into the mold
cavity. The sensor cable is attached to a
sensor adapter mounted outside of the
mold.
TOP OF MOLD
SECTION A:A
A
A
SENSOR
ELECTRONICS
CASE
Because the load washer sensor relies
on the ejector sleeve to transfer pressure
from the cavity to the sensor surface, the
head of the ejector sleeve must contact
at least 80% of the loading surface. If
this is not attainable, a spacer may be
created to facilitate the correct loading.
Read and follow all instructions to install
the load washer sensor; refer to “Alternate
Installation Overview” on page 9 for
spacer installation instructions.

6 RJG, Inc. Piezoelectric Load Washer Sensor 211M18 | Product Manual
Date: 01.27.2022
Drawn: K.J.Brettschneider
Check: M.Groleau
Design:
Description: 211M18 Sensor
Installation
NOTES:
ENCLOSED EJECTOR BOX SUGGESTED. 1.
DO NOT SCALE PRINT 2.
BREAK ALL SHARP EDGES, 0.005 [0.03] R MAX 3.
DIMENSIONS IN INCHES [MM], UNLESS NOTED 4.
TOLERANCES UNLESS SPECIFIED: 5.
XXX =
0.003 [0.08]
XX = 0.01 [0.3]
ANGLES = 3 30
Drawing Title: 211M18-03
B
DIA of Sleeve Head + 0.12 [3.0]
if Sleeve Head > Sensor DIA
.67
+
-
.01
.00
16.9
+ 0.3
0
.263±.003
6.67±0.08
.310
+
-
.003
.000
7.87
+ 0.08
0
0.03-0.06
[0.76–1.52]
Sleeve Head Counterbore
.01
+
-
.01
.00
0.25
+ 0.25
0
not to exceed 20% of
part wall thickness
DETAIL B
SCALE 3 : 1
Piezoelectric Load Washer Sensor 211M18 Standard Installation
INSTALLATION SPECIFICATIONS

Product Manual | Piezoelectric Load Washer Sensor 211M18 7
i
SENSOR POCKET
The sensor pocket is machined into the
ejector retainer plate.
• The pocket must be concentric 0.67”
+0.01/‑0.000 (16,9mm +0,30/‑0,00 [ 1at
right]).
• Machine the pocket width for the sensor
stem 0.28” (7 mm [ 2at right]) MIN.
• Sensor pocket and stem depth must be
0.310” +0.003/‑0.00 (7,87 mm +0,08/‑0,00
[3at right]).
• Machine the core pin pocket 0.263”
±0.003 (6,67 mm ±0,07 [ 4at right]).
EJECTOR SLEEVE POCKET
Machine the ejector sleeve pocket into the
ejector plate. The ejector sleeve must have
0.01” +0.01/‑0.00 (0,25 mm +0,25/‑0,00
[5iat right]) MIN clearance.
NOTESLThe ejector sleeve head clearance
must not exceed 20% of the part wall
thickness.
EJECTOR SLEEVE COUNTERBORE
OPTIONAL
If the ejector sleeve head is larger than
the sensor head, the ejector sleeve pocket
must be counter‑bored at a depth of 0.03–
0.06” (0,76–1,52 mm [ 6at right]).
Machine the countersink into the ejector
plate the diameter of the ejector sleeve
plus 0.12” (3,0 mm [ 7at right]).
1ø 0.67” +0.01/‑0.00 (16,9 mm +0,30/‑0,00)
20.28” (7 mm) MIN
30.310” +0.003/‑0.00 (7,87 mm +0,08/‑0,00)
40.263” ±0.003 (6,67 mm ±0,07)
50.01” +0.01/‑0.00 (0,25 mm +0,20/‑0,00) MIN i
60.03–0.06” (0,76–1,52mm)
7Sleeve Head Ø + 0.12” (3mm) if Sleeve Head
Ø > Sensor Ø
INSTALLATION SPECIFICATIONS (continued)
4
6
7
3
5
2
1

Piezoelectric Load Washer Sensor 211M18 | Product Manual
8
CABLE CHANNEL
Machine a cable channel width of 0.28”
(7mm [ 1AT RIGHT]) MIN and depth of
0.310” (7,87 mm) to accommodate the
sensor stem for 1.89” (48mm [ 2at right])
from center of sensor head: this is also the
minimum bend length.
CAUTIONaDo not bend the sensor cable
closer than the minimum bend
length; failure to comply will result
in damage to equipment.
Machine a cable channel width and depth
from the end of the sensor stem pocket out
of the mold of 0.25” (6mm [ 2at right]).
10.28” (7 mm) wide by 0.310” (7,87 mm) deep
21.89” (48 mm)
30.25” (6 mm)
13
2
INSTALLATION SPECIFICATIONS (continued)

Product Manual | Piezoelectric Load Washer Sensor 211M18 9
ALTERNATE INSTALLATION OVERVIEW
If the head of the ejector sleeve does not
contact at least 80% of the loading surface,
a spacer must be created to facilitate the
correct loading.
A channel is machined into the mold for
the sensor cable and sensor head. The
sensor head is placed under the spacer
and ejector sleeve in the mold ejector
retainer plate. An ejector sleeve core pin
extends through the sensor head, spacer,
and ejector sleeve into the mold cavity.
The sensor cable is attached to a sensor
adapter mounted outside of the mold.
TOP OF MOLD
A
A
SENSOR
ELECTRONICS
CASE

10 RJG, Inc. Piezoelectric Load Washer Sensor 211M18 | Product Manual
ALTERNATE INSTALLATION SPECIFICATIONS
Date: 01.27.2022
Drawn: K.J.Brettschneider
Check: M.Groleau
Design:
Description: 211M18 Sensor
Installation
NOTES:
ENCLOSED EJECTOR BOX SUGGESTED. 1.
DO NOT SCALE PRINT 2.
BREAK ALL SHARP EDGES, 0.005 [0.03] R MAX 3.
DIMENSIONS IN INCHES [MM], UNLESS NOTED 4.
TOLERANCES UNLESS SPECIFIED: 5.
XXX =
0.003 [0.08]
XX = 0.01 [0.3]
ANGLES = 3 30
Drawing Title: 211M18-04
C
Spacer
Contact Surface
.410
+
-
.003
.000
10.41
+ 0.08
0
.67
+
-
.01
.00
16.9
+ 0.3
0
DIA of Sleeve Head + 3.0 [.12]
if Sleeve Head > Sensor DIA
.263±.003
6.67±0.08
0.03-0.06
[0.76–1.52]
Sleeve Head
Counterbore
.01
+
-
.01
.00
0.25
+ 0.25
0
not to exceed 20% of
part wall thickness
DETAIL C
SCALE 3 : 1
Customer-supplied spacer required if head of sleeve contacts
less than 80% of sensor loading surface.
Piezoelectric Load Washer Sensor 211M18 Optional Installation

Product Manual | Piezoelectric Load Washer Sensor 211M18 11
ALTERNATE INSTALLATION SPECIFICATIONS (continued)
SENSOR AND SPACER POCKET
The sensor pocket is machined into the
ejector retainer plate.
• The pocket must be concentric 0.67”
+0.01/‑0.000 (16,9mm +0,30/‑0,00 [ 1at
right]).
• Machine the pocket width for the sensor
stem 0.28” (7 mm [ 2at right]) MIN.
• Sensor, spacer, and stem pocket depth
must be 0.410” +0.01/‑0.00 (10,41 mm
+0,25/‑0,00 [ 3at right]).
SPACER
Spacers are customer‑supplied and must
be made to match the diameter of the core
pin.
• The spacer height is 0.100” ±0.003
(2,54mm ±0,08 [ 4at right]).
• Spacer outer DIA is concentric 0.500”
±0.003 (12,70 mm ±0,08 [ 5at right]).
• Provide a pin diameter clearance inside
the spacer of 0.005” (0,127 mm [ 6at
right]) per side.
EJECTOR SLEEVE AND CORE PIN
POCKETS
Machine the ejector sleeve pocket into the
ejector plate. The ejector sleeve must have
0.01” +0.01/‑0.00 (0,25 mm +0,25/‑0,00
[7 i at right]) MIN clearance.
NOTESLThe ejector sleeve head clearance
must not exceed 20% of the part wall
thickness.
Machine the core pin pocket 0.263” ±0.003
(6,67 mm ±0,07 [ 8at right]).
1ø 0.67” +0.01/‑0.00 (16,9 mm +0,30/‑0,00)
20.28” (7 mm) MIN
30.410” +0.003/‑0.00 (10,41 mm +0,08/‑0,00)
40.100” ±0.003 (2,54 mm ±0,08)
50.500” ±0.003 (12,7 mm ±0,08)
60.005” (0,127 mm) Per Side
70.01” +0.01/‑0.00 (0,25 mm +0,25/‑0,00) MIN i
80.263” ±0.003 (6,67 mm ±0,07)
2
1
3
7
8
4
5
6

Piezoelectric Load Washer Sensor 211M18 | Product Manual
12
CABLE CHANNEL
Machine a cable channel width of 0.28”
(7mm [ 3AT RIGHT]) MIN and depth of
0.310” (7,87 mm) to accommodate the
sensor stem for 1.89” (48mm [ 1at right])
from center of sensor head: this is also the
minimum bend length.
CAUTIONaDo not bend the sensor cable
closer than the minimum bend
length; failure to comply will result
in damage to equipment.
Machine a cable channel width and depth
from the end of the sensor stem pocket out
of the mold of 0.25” (6mm [ 2at right]).
11.89” (48 mm)
20.25” (6 mm)
30.28” (7 mm) wide by 0.25” (6 mm) deep
12
3
ALTERNATE INSTALLATION SPECIFICATIONS (continued)