RJG Lynx OR2-M User manual

PRODUCT MANUAL
Training and Technology for injecTion Molding
Lynx™ Shielded dual-Relay
Output MOdule
OR2‑M

PRINT DATE 11.11.2019
REVISION NO. 1

Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. i
PRODUCT MANUAL
Lynx™ Shielded dual-Relay Output
MOdule
OR2‑M
INTRODUCTION
DISCLAIMER V
PRIVACY V
ALERTS V
PRODUCT DESCRIPTION
APPLICATIONS 1
PROCESS MONITORING AND CONTROL 1
OPERATION 2
PART SORTING OUTPUTS 2
CONTROL OUTPUTS 2
PRODUCTION OUTPUTS 3
INDICATOR OUTPUTS 3
SEQUENCE MODULE OUTPUTS 3
MACHINE SEQUENCE OUTPUTS 4
VALVE GATE OUTPUTS 4
DIMENSIONS 5
CABLE LENGTH 5

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INSTALLATION
INSTALLATION OVERVIEW 7
OR2‑M 7
eDART CONNECTION 7
INSTALLATION SPECIFICATIONS 8
REQUIREMENTS 8
MOUNTING 8
WIRING 8
CONNECTIONS 9
MAINTENANCE
CLEANING 11
REGULAR CLEANING 11
TESTING 11
eDART VERSION 9.XX SOFTWARE 11
eDART VERSION 10.XX SOFTWARE 13
FUSE REPLACEMENT 15
REQUIREMENTS 15
TOOLS 15
INSTRUCTIONS 15
WARRANTY 18
RJG, INC. STANDARD WARRANTY 18
PRODUCT DISCLAIMER 18
PRODUCT MANUAL
lynx™ Shielded dual-Relay Output
MOdule
OR2‑M

Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. iii
PRODUCT MANUAL
lynx™ Shielded dual-Relay Output
MOdule
OR2‑M
TROUBLESHOOTING
COMMON SORTING SETUPS 19
GOOD OR FAIL‑SAFE SORTING 19
THREE‑WAY SORTING 19
SORTING ERRORS AND SOLUTIONS 20
ROBOT SETTINGS AND TIMING 20
PINCHED OR STUCK PARTS 21
EQUIPMENT FAILURES 21
HUMAN ERROR 21
CUSTOMER SUPPORT 22
RELATED PRODUCTS
COMPATIBLE PRODUCTS 23
SHIELDED DUAL‑RELAY OUTPUT MODULE CABLE C‑OR2‑M‑3M 23
LYNX CABLES CE‑LX5 23
eDART PROCESS CONTROLLER 23
SIMILAR PRODUCTS 24
LYNX SURFACE‑MOUNT DUAL‑RELAY OUTPUT MODULE OR2‑S 24
LYNX COMMUNICATIONS ADAPTER
DIN/LX‑D 24

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Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. 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 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:
Term
A definition of a term or terms used in the
text.
NOTE A note provides additional information
about a discussion topic.
CAUTION A caution is used to make the
operator aware of conditions that can cause
damage to equipment and/or injury to personnel.

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Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. 1
PRODUCT DESCRIPTION
The Lynx shielded dual‑output relay module
is a DIN‑rail‑mounted module that is wired
to the molding machine in order to provide
output signals from the eDART®for part sorting,
injection enable, or transfer (V→P).
APPLICATIONS
PROCESS MONITORING AND CONTROL
The eDART system requires various inputs
from the injection molding machine in order to
accurately calculate significant process values for
monitoring and control.
The OR2‑M supplies two contact relays from
the eDART to the molding machine, or robot, to
output to sorting, control, production, indicator,
sequence module, machine sequence, or valve
gate (requires eDART valve gate software).

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OPERATION
PART SORTING OUTPUTS
The OR2‑M is often used to provide a signal
to sorting equipment to perform sorting
actions. The shielded dual‑relay input module
cable C‑OR2‑M‑3M is wired to the sorting
equipment input card which accepts the signal;
the C‑OR2‑M‑3M is connected to the OR2‑M,
which collects the signal for use from the
eDART.
In the eDART software, the module is configured
to properly identify and sort parts; the module
may also be configured to stop the machine
after a specified number of reject parts are
created in a specified number of consecutive
cycles.
1. Good Control
Good control sends a signal to a robot that the
last part made is “good” for sorting purposes.
2. Sample Parts Control
Sample parts control turns on a “sample parts”
control—could be used to tell a robot to divert
parts to a special sample location.
3. Excessive Rejects Control
Excessive rejects control turns on “excessive
rejects” control based on a user‑defined number
of rejects within a user‑defined number of
consecutive cycles; the output signal could turn
on some form of an alerting mechanism or it
could shut the machine down entirely.
4. Bad/Reject Control
Bad, or reject, control sends a signal to a robot
that the last part made was “bad” for sorting
purposes.
CONTROL OUTPUTS
1. Injection Enable
The OR2‑M is often used to provide a signal to
the injection molding machine to indicate the
machine that injection is enabled. The shielded
dual‑relay input module cable C‑OR2‑M‑3M is
wired to the machine input card which accepts
the signal; the C‑OR2‑M‑3M is connected to
the OR2‑M, which collects the signal for use
from the eDART. In the eDART software, the
module is configured to properly detect and
enable injection.
2. Machine Transfer
The OR2‑M is often used to provide a signal
to the injection molding machine to indicate
the machine to transfer from pressure to
hold (V→P). The shielded dual‑relay output
module cable C‑OR2‑M‑3M is wired to the
machine input card which accepts the signal;
the C‑OR2‑M‑3M is connected to the OR2‑M,
which collects the signal for use from the
eDART. In the eDART software, the module is
configured to properly detect and enable V→P.
3. Job Start
The OR2‑M can be used in conjunction
with the eDART Job Started tool to allow
a machine to run only after the eDART job
is running. The shielded dual‑relay output
module cable C‑OR2‑M‑3M is wired to the
machine input card, which accepts the signal;
the C‑OR2‑M‑3M is connected to the OR2‑M,
which collects the signal for use from the eDART
when the specified job is running.

Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. 3
PRODUCTION OUTPUTS
The OR2‑M can be used to provide a signal
to a light indicator tree that displays the status
of a running molding machine from the eDART
software to indicate the status of a process.
The shielded dual‑relay input module cable
C‑OR2‑M‑3M is wired to the light indicator tree
which accepts the signal; the C‑OR2‑M‑3M is
connected to the OR2‑M, which collects the
signal for use from the eDART.
1. Job Down
The job down production output sends a signal
to a light indicator for display.
2. Job Running
The job running production output sends a
signal to a light indicator for display.
3. Job Started
The job started production output sends a signal
to a light indicator for display.
INDICATOR OUTPUTS
The OR2‑M can be used to provide a signal
to a light indicator tree that displays the status
of a running molding machine from the eDART
software to indicate if a process is running
within its preset limits. The shielded dual‑relay
input module cable C‑OR2‑M‑3M is wired to
the light indicator tree which accepts the signal;
the C‑OR2‑M‑3M is connected to the OR2‑M,
which collects the signal for use from the
eDART.
1. Process Good
The process good indicator output sends a
signal to a light indicator for display.
2. Process Alarm
The process alarm indicator output sends a
signal to a light indicator for display.
3. Process Warning
The process warning indicator output sends a
signal to a light indicator for display.
SEQUENCE MODULE OUTPUTS
The OR2‑D can be used to provide a signal to
a robot, PLC, etc. that indicates the current
status of the molding machine cycle’s sequence,
including the statuses listed below:
• Injection Forward
• Screw Run
• Mold Opening
• Mold Closing
• Machine in Manual
• Pump On
• Mold Clamped
• Mold Fully open
• First Stage
• Second Stage
• Fill
• Shuttle Position
• Core Pull
• Pin Pull
• Ejection
• Unknown
• Auxiliary
OPERATION (continued)

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MACHINE SEQUENCE OUTPUTS
The eDART software calculations of times and
process variables are based on internal machine
sequences; these are calculated by the eDART
software using the actual machine sequence
module inputs. Each of the following machine
sequences represents a status or function of
the machine and can be sent from the OR2‑D
module as an output signal:
• Injection Forward
• Fill
• Pack
• Hold
• Plastic Cooling
• Screw Run
• Mold Opening
• Mold Closing
• Mold Clamped
• Mold fully open
• Auxiliary
VALVE GATE OUTPUTS
The OR2‑M is often used to provide a signal
to a valve gate to open or close the gate.
The shielded dual‑relay output module
cable C‑OR2‑M‑3M is wired to the valve
gate solenoid which accepts the signal; the
C‑OR2‑M‑3M is connected to the OR2‑M,
which collects the signal for use from the
eDART. In the eDART valve gate software,
the module is configured to open, close, or
enable the gate; refer to the eDART Valve Gate
Software manual for all instructions.
1. Open Gate
The valve gate output sends a signal to open a
gate.
2. Close Gate
The valve gate output sends a signal to close a
gate.
3. Enable Gate
The valve gate output sends a signal to enable a
gate.
OPERATION (continued)

Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. 5
DIMENSIONS
CABLE LENGTH
The C‑OR2‑M‑3M is 9.8 ft. (3 m) long.
CABLE LENGTH

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INSTALLATION
INSTALLATION OVERVIEW
The shielded dual‑relay output module is
mounted to a solid surface, such as the machine
frame, inside the molding machine on a DIN
rail.
OR2‑M
The shielded dual‑relay output module cable
C‑OR2‑M‑3M is wired directly to an input
card on the machine, or sorting equipment,
on one end, and connected to the OR2‑M on
the other using the four‑pin connector. The
shielded analog input module is connected
to the ID7‑M‑SEQ (or DIN/LX‑D), or other
shielded module using the integrated amphenol
connector.
eDART CONNECTION
A Lynx cable CE‑LX5 is connected to the Lynx
port on the ID7‑M‑SEQ and a Lynx port on
the eDART to provide it with the machine’s
sequence signals for process monitoring and
control calculations, along with the other
installed machine interface module signals.

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INSTALLATION SPECIFICATIONS
REQUIREMENTS
CAUTION Before beginning OR2‑M
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.
MOUNTING
Mount the OR2‑M module to a solid surface—
such as the molding machine frame—using the
supplied 1.38” (35 mm) DIN rail. A clearance
height of 6” (152,4 mm) from the face of the
module is recommended.
NOTE Modules and connecting cables must
be located away from any static sources, such as
feeder tubes and material hoppers.
WIRING
The OR‑M is interfaced to a machine or robot’s
input card; the machine can then be configured
to stop if excessive reject parts are being
produced, transfer the machine, or the robot
can be configured to save only good parts.
Determine the input voltage required by the
machine/robot to facilitate the desired action
(most machines/robots require 24 V DC).
CAUTION Always apply the appropriate
backups provided by the machine or robot
manufacturer.
The C‑OR2‑M‑3M cable has colored‑coded
wires to simplify installation. Refer to the
following table for the correct wire/signal
combinations for installation.
RELAY SIGNAL COLOR
* 1A 30 V DC CONTACT RATING *
Contact Relay 1 Normally Open Brown
Contact Relay 1 Common Black
Contact Relay 1 Normally Closed Blue
Contact Relay 2 Normally Open Brown
Contact Relay 2 Common Black
Contact Relay 2 Normally Closed Blue
Attach the common wire for contact relay 1
to the 24 V DC power source of the machine/
robot controller; attach the normally open wire
for contact relay 1 to the 24 V DC machine/
robot input/output (I/O) card input terminals.

Product Manual | Lynx™ Shielded Dual‑Relay Output Module OR2‑M RJG, Inc. 9
WIRING (continued)
RJG, Inc. recommends the user of the included
quench‑arcs with dry contacts, preferably
installed across the load—however, the
quench‑arcs may also be placed across the
contacts by attaching to the cable pigtails—refer
to the figure below for installation.
Quench‑arcs
Quench‑arcs increase relay life and
reduce electromagnetic interference
(EMI) emissions. It is preferred that the
quench‑arcs are attached across the
load. However, the quench‑arcs may
alternately be placed across the contacts
by attachment to the cable pigtails.
INSTALLATION SPECIFICATIONS (continued)
CONNECTIONS
Connect the OR2‑M to the shielded
sequence module ID7‑M‑SEQ—or shielded
communications module DIN/LX‑D—using the
integrated, side‑mount amphenol connector.
Connect the C‑OR2‑M‑3M cable to the OR2‑M
module.
QUENCH-ARC
OR2-M MODULE
C-OR2-M-3M CABLE
C-OR2-M-3M CABLE
NC
NC
NO
NO
24 V SUPPLY
24 V SUPPLY
QUENCH-ARC

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MAINTENANCE
The shielded dual‑relay output 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®
TESTING
Test the OR2‑M after assignment using the Part
Diverter Controls tool in version 9.xx software,
or in Machine Setup utilities in version 10.xx
software.
eDART VERSION 9.XX SOFTWARE
1. Part Sorting
The OR2‑M must be set up in the Sensor
Locations, Alarm Settings, and Part Diverter
Controls functions in order to sort parts.
Assign the OR2‑M as a Sorting Output sensor
type in the Sensor Locations tool; choose the
sensor location from the drop‑down menu.
The Alarm Settings tool is used to set alarms on
specific process values; the software uses the
set process values to sort the parts. Create an
alarm in the Alarm Settings tool for the value on
which to sort; check the box in the Sort column
to apply sorting action to the alarm. The Sort
button in the Part Diverter Controls must also
be selected to sort parts.
In addition, the OR2‑M can be configured in
the Sensor Locations tool to activate an alarm
or stop the machine if an excessive amount of
rejects are produced. Assign the OR2‑M as a
Sorting Output type in the Sensor Locations
tool; choose the Excessive Rejects sensor
location from the drop‑down menu. Define
the reject and consecutive cycle limits in the
Excessive Rejects Output window.
2. Injection Enable
The OR2‑M must be set up in the Sensor
Locations to control injection. Assign the
OR2‑M as a Control Output type in the Sensor
Locations tool; choose the Inject Enable sensor
location from the drop‑down menu.
The injection enable function allows the
connected relay contact closer to stay closed
as long as the system is operating properly;
if a failure occurs the output opens, and the
machine stops to prevent any damage.

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3. V→P
The OR2‑M is set up to transfer the injection
molding machine from the velocity stage to the
pressure stage in the cycle. The OR2‑M must
be set up in the Sensor Locations.
To test if the input is detected by the machine,
use the V→P Output Test function. The Velocity
to Pressure Transfer tool Output Test function
is accessible from the Settings menu. Select
Output Test, then press the on and off buttons
and check the press controller’s diagnostic page
for changes in the input. The eDART disables the
test button when the press is cycling.
If the inputs are correct and detected by the
machine, perform the following to ensure the
correct function:
Set up a process (DECOUPLED MOLDING®II
or III) with transfer from pressure to hold based
on the machine’s screw position.
Make sure the process ends with little cushion,
likely bottoming out shortly after transfer—this
will prevent mold damage if the transfer does
not work.
Make a template.
Place the cursor on the Cycle Graph slightly
before the machine pressure curve can be seen
dropping into hold.
Record the volume measurement from the
cursor. Open the V→P tool and select the check
mark next to the “Injection Volume Exceeds”
field to enable control; enter the recorded
volume measurement and select the correct
units of measure.
Enable the machine’s external transfer; some
machines allow both external and internal and
some force the use of only one or the other.
The V‑>P volume switchover should show
“Active” and the machine should transfer earlier
as shown below
The transfer point should be movable by
changing the volume number in the V→P tool.
If the curve does not change from the template
(as shown below) then the machine is not
accepting the transfer signal from the eDART.
The backup set points for time, position, or
pressure on the machine must be verified and
used during cavity pressure transfer control.
In the event that the cavity pressure transfer
control input is not detected by the machine
controller, the backup set points prevent
damage to the tool.
TESTING (continued)