RJG Lynx IA1-S-VI-24 User manual

PRODUCT MANUALPRODUCT MANUAL
Training and Technology for Injection Molding
L™ S- A I
M  24 V P
S
IA1‑S‑VI‑24

PRINT DATE 01.16.2023
REVISION NO. 0

i
Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
PRODUCT MANUAL
L™ S- A I
M  24 V P S
IA1‑S‑VI‑24
INTRODUCTION
DISCLAIMER III
PRIVACY III
ALERTS III
PRODUCT DESCRIPTION
APPLICATIONS 1
PROCESS MONITORING AND CONTROL 1
OPERATION 1
INJECTION PRESSURE 1
SCREW POSITION/VELOCITY 1
DEW POINT 1
OTHER SUPPORTED SENSOR TYPES 2
DIMENSIONS 3
CABLE LENGTH 3
INSTALLATION
INSTALLATION OVERVIEW 5
IA1‑S‑VI‑24 5
eDART OR COPILOT SYSTEM CONNECTION 5
INSTALLATION SPECIFICATIONS 6
REQUIREMENTS 6
SWITCHING 0–10 V INPUT TO 4–20 MA INPUT 6
MOUNTING 7
WIRING 7
CONNECTIONS 7
eDART SYSTEM SOFTWARE SETUP 8
eDART SYSTEM VERSION 9.XX 8
eDART SYSTEM VERSION 10.XX 9
COPILOT SYSTEM SOFTWARE SETUP 9
MATH EQUATIONS FOR ANALOG INPUTS 9

ii Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
MAINTENANCE
CLEANING 11
REGULAR CLEANING 11
FUSE REPLACEMENT 11
WARRANTY 12
RJG, INC. STANDARD WARRANTY 12
PRODUCT DISCLAIMER 12
TROUBLESHOOTING
COMMON INSTALLATION ERRORS 13
NEGATIVE SCALING FOR STROKE 13
FALSE CYCLE START ON PRESS POWER‑UP 13
INCORRECT INJECTION PRESSURE SCALING 13
CUSTOMER SUPPORT 14
RELATED PRODUCTS
COMPATIBLE PRODUCTS 15
SURFACE‑MOUNT ANALOG INPUT MODULE CABLE C‑IA1/LX‑4M 15
LYNX CABLES CE‑LX5 15
SIMILAR PRODUCTS 16
LYNX COMMUNICATIONS ADAPTER
DIN/LX‑D 16
LYNX SHIELDED ANALOG INPUT MODULE IA1‑M‑V 16
PRODUCT MANUAL
L™ S- A I
M  24 V P S
IA1‑S‑VI‑24

iii
Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
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 2018 RJG, Inc. content
documentation copyright 2018 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.

iv Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
NOTES

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
PRODUCT DESCRIPTION
The Lynx™ surface‑mount analog input
module IA1‑S‑VI‑24 is a surface‑mounted
module that is wired to the molding
machine in order to collect 0–10VDC or
4–20 mA signals from analog measurement
devices, providing information such as
injection pressure, plastic pressure, screw
position, and temperature. In addition the
module can supply a 24V power source to
some sensors.
APPLICATIONS
PROCESS MONITORING AND CONTROL
The IA1‑S‑VI‑24 gathers 0–10V/4–20 mA
signals from molding machine analog
inputs for the eDART. The eDART performs
computations using the signals from
the injection molding machine or other
measurement devices for various process
parameters during a typical cycle.
OPERATION
The IA1‑S‑VI‑24 supplies the eDART or
CoPilot system with injection pressure,
stroke position/velocity, or dew point
signals from the machine’s output card.
In addition, the IA1‑S‑VI‑24 is compatible
with other measurement devices that
supply a 0–10V/4–20 mA signal for
process monitoring, including: air flow,
barrel temperature, coolant flow rate,
coolant pressure, coolant temperature,
delta pressure, dryer temperature, ejector
pin (indirect) pressure, hydraulic pressure,
line temperature, melt pressure, mold
deflection, mold temperature, power
consumption, revolution rate, and vacuum.
INJECTION PRESSURE
The IA1‑S‑VI‑24 is often used to acquire
an injection pressure signal from
electric injection molding machines. The
surface‑mount analog input module cable
C‑IA1/LX‑4M is wired to the machine output
card which provides the signal; the C‑IA1/
LX‑4M is connected to the IA1‑S‑VI‑24,
which collects the signal for use with the
eDART or CoPilot system. In the software,
the module is configured to read the
voltages as pressures.
SCREW POSITION/VELOCITY
The IA1‑S‑VI‑24 is often used to acquire
an screw position/velocity signal from
electric injection molding machines. The
surface‑mount analog input module cable
C‑IA1/LX‑4M is wired to the machine output
card which provides the signal; the C‑IA1/
LX‑4M is connected to the IA1‑S‑VI‑24,
which collects the signal for use with the
eDART. In the eDART or CoPilot system
software, the module is configured to read
the voltages as position/velocity.
DEW POINT
The IA1‑S‑VI‑24 can be used to acquire a
dew point measurement from the Vaisala
DRYCAP® Transmitters DMT142 or DMT143.
The DMT142 or DMT143 is connected to
the IA1‑M‑V using a cable (included with
DMT142 or DMT143 purchase from RJG),
which collects the signal for use with the
eDART or CoPilot system. In the software,
the module is configured to read the
voltages as dew point.

2Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
OTHER SUPPORTED SENSOR TYPES
The IA1‑S‑VI‑24 also supports the additional
following sensor types:
• Ejector Pin (indirect)
• Hydraulic Pressure
• Mold Temperature
• Barrel Temperature
• Coolant Temperature
• Coolant Flow Rate
• Delta Pressure
• Revolution Rate
OPERATION (continued)
• Mold Deflection
• Power Used
• Dryer Temperature
• Air Flow
• Melt Pressure
• Line Temperature
• Vacuum

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
DIMENSIONS
CABLE LENGTH
CABLE LENGTH
The C‑IA1/LX‑4M is 13ft. (4 m) long.

4Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
NOTES

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
INSTALLATION
INSTALLATION OVERVIEW
The surface‑mount analog input module
is mounted to a solid surface, such as the
machine or mold.
IA1SVI24
The surface‑mount analog input module
cable C‑IA1/LX‑4M is wired directly to
the machine (to an output card) on one
end—or to some other 0–10V/4–20 mA
measurement device—and connected
to the IA1‑S‑VI‑24 on the other using the
four‑pin connector.
eDART OR COPILOT SYSTEM
CONNECTION
The surface‑mount analog input module is
connected to the eDART or CoPilot system
using a CE‑LX5 Lynx cable.
CE-LX5 CABLE TO eDART
or CoPilot SYSTEM
C-IA1/LX-4MM CABLE TO
MACHINE OR EQUIPMENT

6Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
INSTALLATION SPECIFICATIONS
The instructions that follow are a general
guide; actual steps necessary to install
this product will vary based on injection
molding machine manufacturer, model, and
options.
The required machine signals can often be
obtained from the machine’s output card.
REQUIREMENTS
CAUTIONaBefore beginning IA1‑S‑VI‑24
installation, disconnect and lockout/
tag‑out any and all power to the
molding machine. Failure to comply
will result in personal injury or
death, and damage or destruction
of equipment.
SWITCHING 010 V INPUT TO 420 MA
INPUT
The Lynx surface‑mount analog input
module is shipped configured for 0–10V
operation. To configure the module for
4–20mA operation, perform the following
steps:
NOTESLRemove all cables from the module,
and remove module from mounting
location if already mounted.
1. Remove Lid.
• Remove four (4) M4 x 20 screws from
module; remove lid from module.
2. Locate the jumper locations JP1( 1
below) and JP2 ( 2below).
3. Install 4–20mA Jumpers.
• Install jumpers into jumper locations JP1
and JP2. The jumpers required are taped
to the lid.
CAUTIONaDo not remove or install any other
jumpers. Failure to comply will
result in personal injury or death,
and damage or destruction of
equipment.
1
2

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
MOUNTING
Mount the IA1‑S‑VI‑24 module to a solid
surface—such as the molding machine
or mold—using the supplied 10‑24 x 1.75”
socket head cap screws (2).
NOTESLModules and connecting cables
must be located away from any
static sources, such as feeder tubes
and material hoppers.
WIRING
The C‑IA1/LX‑4M cable has colored‑coded
wires to simplify installation. Refer to the
table below for the correct wire/signal
combinations for installation.
INPUT FUNCTION COLOR
0–10V + Signal Blue
0VDC
Common – Signal White
+ 24V 24 V Power Black
+0V Sensor Power
Common Brown
INSTALLATION SPECIFICATIONS (continued)
Attach the 0VDC (white) wire to the
common terminal of the injection molding
machine 0–10V I/O card. Attach the 0–10V
(blue) wire to the signal of the machine.
If the associated sensor requires power
from the IA1‑S‑VI‑24, attach the 0V DC
(brown) wire to the common terminal of the
sensor; attach the 24V DC (black) wire to
the sensor to supply it with power.
If a 4–20 mA sensor is used, refer to
“Switching 0–10 V Input to 4–20 mA Input”
on page 6 to appropriately alter the
signal to work with the IA1‑S‑VI‑24.
NOTESLNote the signals which are wired
to the machine for future software
setup and use.
CONNECTIONS
Connect the C‑IA1/LX‑4M cable to the
IA1‑S‑V‑24 module. Connect a CE‑LX5 Lynx
cable to the IA1‑S‑V‑24 module and eDART
or CoPilot system.

8Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
eDART SYSTEM SOFTWARE SETUP
Each sensor type must be fully‑defined in the software for the IA1‑S‑VI‑24 and eDART
system to provide accurate data. Always read and perform the following instructions to set
up the IA1‑S‑VI‑24 module in the eDART system software.
eDART SYSTEM VERSION 9.XX
1. Select the Sensor Type “0 - 10V Input” in
Sensor Locations and Scaling.
2. With the motor or machine (depending
on the sensor type) off/in standby,
measure and record the voltage—the
voltage should be displayed in the
“Value” column.
3. Measure and record the actual voltage
at maximum—the voltage should be
displayed in the “Value” column. Record
the machine value for the measurement
at this time, as well.
For example, if using the IA1‑S‑VI‑24
to acquire injection pressure from the
machine, record the machine’s injection
pressure displayed on the controller.
4. Subtract the low voltage value recorded
in step 2 from the high voltage value
recorded in step 3.
5. Select the Setup button in Sensor
Locations and Scaling.
6. Select the sensor model number from
the drop-down menu; if not listed choose
“Other”.
7. Select the sensor type from the
drop-down menu.
8. Enter the machine value recorded in
step 3 into the Sensor Full Scale field,
and select the appropriate units of
measurement.
9. Enter the change in voltage found in
step 4 in the “when signal shifts by”
field.
10. Select Accept to save the entered
information.

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
eDART SYSTEM VERSION 10.XX
1. Drag and drop the input from the
Available Sensor list in Machine Setup/
INPUTs to the desired position.
2. Click the “i” on the analog input to open
the Analog Input Scaling window.
3. With the motor or machine (depending
on the sensor type) off/in standby,
measure and record the voltage.
4. Measure and record the actual voltage at
maximum; record the machine value for
the measurement at this time, as well.
For example, if using the IA1‑S‑VI‑24
to acquire injection pressure from the
machine, record the machine’s injection
pressure displayed on the controller.
5. Enter the machine value recorded in step
4 into the Maximum field, and select the
appropriate units of measurement.
6. Enter the maximum voltage recorded
in step 4 into the Voltage at Maximum
Pressure field.
7. Enter the voltage recorded in step 3 into
the Voltage at 0 field.
8. Select Save to save the entered
information.
SOFTWARE SETUP (continued)
COPILOT SYSTEM SOFTWARE SETUP
Each sensor type must be fully‑defined in
the software for the IA1‑S‑VI‑24 and CoPilot
system to provide accurate data. Refer to
the CoPilot™ System Software User Guide
to set up the IA1‑S‑VI‑24 module in the
CoPilot system software, available online
for download at www.rjginc.com.
MATH EQUATIONS FOR ANALOG INPUTS
Alternately, the following math equations
may be used to determine injection
pressure, screw position, and velocity
maximum voltages if voltages for hold
pressure, position shot size, or velocity
setting are known:
1. Injection Pressure
Volts
xMAX Pres-
sure =Volts at MAX Pres- sure
Hold Pressure
Setting
2. Screw Position
Volts
+(De-
comp x MAX Pressure)=
Volts
at MAX
Position
Position Shot
Size
3. Velocity
Volts x MAX Velocity = Volts at MAX Ve-
locity
Velocity Setting

10 Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
NOTES

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
MAINTENANCE
The surface‑mount analog input module
requires little to no maintenance provided
that all installation instructions are
followed.
CLEANING
REGULAR CLEANING
Cables must be installed in areas free from
oil, dirt, grime, and grease.
RJG, Inc. recommends the following
cleaners:
• Microcare MCC‑CCC Contact Cleaner C
• Microcare MCC‑SPR SuprClean™
• Miller‑Stephenson MS‑730L Contact
Re‑Nu®
FUSE REPLACEMENT
The 24V output supply is fused—a spare
fuse is provided on the board inside the
IA1‑S‑VI‑24 module enclosure.
Fuse part number: Wickman 3950160044
NOTESLRemove all cables from the module,
and remove module from mounting
location if already mounted.
1. Remove Lid.
• Remove four (4) M4 x 20 screws from
module; remove lid from module.
2. Remove the used 24 V fuse ( 1below)
and discard.
3. Insert new 24V fuse.
A spare 24V fuse ( 2below) is included
inside the module.
4. Reinstall Lid.
• Install lid using four (4) M4 x 20 screws.
1
2

12 Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
WARRANTY
RJG, INC. STANDARD WARRANTY
RJG, Inc. is confident in the quality and
robustness of the surface‑mount analog
input module, and so are offering a
one‑year warranty. RJG’s products are
guaranteed against defects in material
and workmanship for one year from the
original date of purchase. The warranty is
void if it is determined that the adapter was
subjected to abuse or neglect beyond the
normal wear and tear of field use, or in the
event the adapter box has been opened by
the customer.
PRODUCT DISCLAIMER
RJG, Inc. is not responsible for the
improper installation of this equipment, or
any other equipment RJG manufactures.
Proper RJG equipment installation does
not interfere with original equipment
safety features of the machine. Safety
mechanisms on all machines should never
be removed.

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Product Manual | Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24
INCORRECT INJECTION PRESSURE
SCALING
Problem: Injection pressure scaling is
incorrect.
Solution: The eDART system and Lynx
sensors eliminate the need for the manual
scaling steps if injection pressure (for
electric machines) comes from either a
nozzle pressure sensor or an electrical
signal from the machine. However, if
signals from another source are used, then
scaling must be manual input in the eDART.
The electrical signal for pressure is usually
0–10V ,with a “low” voltage (not always
zero) being no pressure and a “high”
voltage (not always 10V) being the highest
pressure. Compare the machines reported
hold pressure to the eDART‑reported
pressure to determine whether a scaling
adjustment is necessary.
TROUBLESHOOTING
COMMON INSTALLATION ERRORS
NEGATIVE SCALING FOR STROKE
Problem: Negative value was entered in
stroke scaling.
Solution: The analog input module cannot
see negative voltages. The wiring must
have the positive (+) terminal on the analog
input above the negative (‑) terminal.
The eDART determines the stroke direction
using the Screw Run signal. It will invert the
signal automatically if necessary to get a
positive volume and stroke curves, and to
analyze flow of material.
If there is no machine sequence module
input for Screw Run positive numbers for
full scale must still be used; set the screw
direction correctly in “Sequence Settings”.
The stroke signal should ascend positively
while the material is being injected into the
mold; the zero of the screw (screw bottom)
must also be set.
FALSE CYCLE START ON PRESS
POWERUP
Problem: Job on eDART is started before
machine is powered on.
Solution: Always power the eDART on after
the machine is powered on.
Analog signals tend have a spike or a
sudden “lurch” from zero to a specific
position voltage. Often the eDART will
interpret the forward jump of the stroke
signal as the cycle start. Sumitomo
machines are particularly prone to this
false trigger problem because a calibration
cycle is performed at each power‑up.

14 Lynx™ Shielded Analog Input Module IA1‑S‑VI‑24 | Product Manual
CUSTOMER SUPPORT
Contact RJG’s Customer Support team by
phone or email.
RJG, Inc. Customer Support
P: 800.472.0566 (Toll Free)
P: +1.231.933.8170
email: [email protected]
www.rjginc.com/support