Synventive eGate Specification sheet

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Company
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Products
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Application
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Technology
eGate® Hot Runner System
Instruction Manual / Installation Guide
SVC-17-0021_EN-Rev1.0 EN 10 / 2012 RK
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

EN
CP
TA
Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 2 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Introduction
Dear customers,
We would like to take this opportunity to thank you for your decision to deploy a Synventive eGate® Controller. We are proud
to provide you with a high quality standard in pin electronic actuator controller systems. If you have any questions on the
applications and the product as such, do not hesitate and contact us by phone or personally.
This manual is designed as a tool for installation, operation and maintenance of your Synventive eGate® Controller and
guideline for securing occupational health and safety in connection with the use of this system. You have to carry out any work
in compliance with the instructions contained herein. The manual contains essential information, arranged to ensure their
general applicability to all Synventive eGate® Controllers.
The employer is exclusively responsible for the protection of workers. The employer therefore has to inform the workers of the
safe handling with machinery and its safety-related parts, to train them and to make sure that the machinery is only operated
by trained, qualied personnel.
The employer has to provide the necessary personal protective equipment (PPE), such as protective gloves, hearing
protection, protective shields etc. In no case does the documentation provided by Synventive release the employer from its
obligations. Synventive does not assume any responsibility for harm done to people in spite of application of the provided
documentation.
Synventive’s recommendations regarding the use of certain Synventive products are based on our best knowledge, but do not
release you from your obligation to carry out your own calculations and tests to ensure compatibility with the injection mold as
well as to determine the product’s compatibility with your technological process.
This manual is intended for toolmakers that deploy controller systems for their electronic actuators in their injection molding
processes and for end users, as well as processing plants. If you are a toolmaker, please hand this manual to the end users
along with the eGate® Controller.
This document is the property of Synventive Molding Solutions and contains important and condential information.
The document and its parts shall not be in any way copied, sold or disclosed to anyone, as a whole or in parts, without the
written consent of Synventive Molding Solutions.
Yours faithfully,
Synventive Molding Solutions
Headquarters:
USA – Peabody, MA
Synventive Molding Solutions
10 Centennial Drive
Peabody, MA 01960
Tel.: [phone]
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Germany – Bensheim
Synventive Molding Solutions GmbH
Heimrodstraße 10
P. O. Box 3123
64625 Bensheim
Tel. :[phone]
Fax :[phone]
Email: [email protected]
China – Suzhou
Synventive Molding Solutions (Suzhou) Co. Ltd.
12B Gang Tian Industrial Square
Suzhou Industrial Park, China 215021
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Customer Service:
North America
24/7 Technical Support Line
1-800-367-5662 – Press 4 from the Main Menu
Europe
Technical Support
[phone] (8:00 am - 5:00 pm)
For after hours service, please contact your
local service representative
Asia
24/7 Technical Support
[phone]-666 (8:30 am - 5:00 pm)
[phone] after hours
© Copyright 2012 Synventive Molding Solutions.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 3 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
1 Safety Instructions
1.1 CE approved Equipment
●Only CE approved equipment rated for application should be used with Synventive Hot Runner Systems.
1.2 Purpose of use of an eGate® Controller System for Hot Runners
1.2.1 Use compatible with the intended Purpose
●The goal of the eGate® Controller System for Hot Runners is to carefully transport the melt with electrically
controlled open/close and motion/position prole from the plastication unit to the cavity with an optimum
distribution concept.
●Synventive eGate® Controller System for Hot Runners are not stand alone systems and must be incorporated in
the injection mold for use.
●All Synventive eGate® Controller System for Hot Runners are used exclusively for the processing of
thermoplastic materials based on the individual requirements of the specied material.
●A max. injection pressure of 30,000 psi (2068 bar) applies to Synventive Hot Runner standard components
(unless otherwise stated).
● Use in conformity with the specied purpose also includes the study and understanding of and the compliance
with all instructions and tasks of the submitted instructions for use.
●Synventive eGate® Controller Systems for Hot Runners may be incorporated only into specially designed
cavities of injection molds.
●To guarantee a reliable operation of the eGate® Controller System for Hot Runners, it is necessary to comply
with the specied periodic inspections and regular maintenance.
1.2.2 Use in conflict with the intended Purpose
●Synventive eGate® Controller System for Hot Runners may be only used in the manner described in section
1.2.1 Use compatible with the intended Purpose. Any other use is excluded. If the eGate® Controller System for
Hot Runners is used in any manner that contradicts the intended purpose, the right to any warranty claims shall
cease to exist.
1.3 Definition of Qualified Persons with Technical Knowledge
Technical knowledge means that personnel must -
●Be capable of reading and fully understand injection molding -, hot runner technique and electrical circuits
●Fully understand the interrelationship of the built-in safety systems
●Have knowledge regarding the function and build-up of technical components.
A qualified person is one who, due to his technical training and experience, has sufficient knowledge
that he can evaluate the work transferred -
●Can recognise possible hazards.
●Can instigate measures to eliminate hazards.
●has the required repair and assembly knowledge.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 4 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
1.4 Safety Instructions within the Instruction Manual
●The eGate® Controller System for Hot Runners is an incomplete machine. When the eGate® Controller System
is tted into a machine, the interaction between the entire machine and the eGate® Controller System, causes
changes to the potential hazards. In particular, the inuence of electrical controls which cause mechanical
movements. This necessitates a hazard analysis and operating instructions for the entire machine.
●These operating instructions are intended to provide information and to prevent hazards when installing the
eGate® Controller System for Hot Runners in the machine as well as information and guidelines for transport,
storage and maintenance (inspection, servicing, repair) of the eGate® Controller System.
●Only by strictly observing these operating instructions, is it possible to prevent accidents and material damage
and ensure fault-free operation of the eGate® Controller System for Hot Runners.
1.5 The eGate® System Instruction Manual / Part of the Synventive
Customer Documentation
●Comply with all safety instructions contained in the customer drawings.
●Use customer drawings for general information only. For detailed information, refer to the supplied Synventive
3D model.
Parts of the Synventive customer documentation are:
●User instruction
●Customer drawings
●Electrical wiring information
● Product Certicate / Hot Runner Check List
●Manifold mounting check list
●Parts list
●3D-Model (in digital form)
●General safety instruction for the Synventive Hot Runner Systems
1.6 Safety Instructions and Symbols used
The following safety instructions and symbols and operating advice are used in this manual. They are highlighted by the
respective word. The described measures are used to prevent injuries and avoid damage to the eGate® Controller System and
must be followed.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 5 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
1.6.1 Symbols of Danger Categorisation
Danger
indicates an imminent hazardous situation which may result in death or serious injury.
Warning
indicates a dangerous situation that may lead to irreversible injury.
Caution
indicates a dangerous situation that may lead to reversible injury.
Notice
indicates a situation that may lead to material damage and provides additional
information on proper procedures and trouble-free labor without the possibility of
personal injury.
1.6.2 Mandatory Safety Signs of the Personal Protective Equipment
Read the user
instruction
Wear safety shoes Wear close-tting
working cloth
Wear headgear Wear protective
goggles
Wear face protection
Wear work gloves Wear apron against
high temperature
Wear hearing
protection
1.6.3 Warning Symbols
General warning Warning of electrical
danger
Warning of hot surface
Warning of overhead
load
Warning of fork lift
trucks operating
Warning of falling
objects
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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 6 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
1.6.4 Product Safety Lable
Electrical danger
1.6.5 Electrical Symbol
Potential earth ground
1.6.6 Components of the eGate® Controller System
●Injection Molding Machine (IMM) is CE approved according 2006/42/EG, 2004/108/EG, 2006/95/EG
●eGate® Hot Runner System is CE approved according 2006/42/EG, 2004/108/EG, 2006/95/EG,
EN ISO 12100 -1:2003/A1:2009, EN ISO 12100-2:2003/A1:2009, EN 60204-1:2006, EN 61000-6-4:2007
●(Pending Safety Approval) eGate® Controller System is CE approved according: EN55022 : 1994 A1 :1995
/ A2 :1998, EN 550011:2007, EN55024.: 1998, EN61000-4-2:1993, EN61000-4-3:1996, EN61000-4-4:1995,
EN61000-4-5:1995, EN61000-4-6:1996, EN61000-4-11:1994, EN61000-6-2:2005, ENV50140:1993
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 7 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
1.7 General Safety Instructions
All safety instructions shall be carefully studied before the operation of the Synventive Hot Runner System is initiated. When
working with the Hot Runner System, all safety instructions contained here in must be followed.
Noncompliance with safety notes and instructions could result in serious injuries.
Danger to Life by Electric Shock
The electrical cables connected to the eGate® Controller System, Injection
Molding Machine and Hot-Runner are under high voltage.
Serious personal injury or death can result from electrical contact.
Electrical work must be carried out by qualied persons.
Verify that all power source connections are properly grounded.
In Emergency case - Switch all systems off.
For first aid contact your medical / safety representing.
Heavy Weight Hazard
Transport and lifting equipment should be operated only by trained personnel.
Use personal protective equipment, such as head gear, safety shoes and work
gloves.
Operate lifting and transport equipment slowly and carefully to avoid uncontrolled
swinging of the manifold.
Lifting and transport equipment for lifting Hot Runner Systems shall be approved
and properly rated taking into account the weight and size of the manifold.
For first aid contact your medical / safety representing.
Hot Surfaces Hazard
Contact between the skin and the hot injection mold could result in burns.
Use personal protective equipment, such as work gloves, apron, sleeves and face
protection, to guard against burns.
When servicing or handling the hot runner system outside the manifold plates
or the injection molding machine, care must be taken to heed the hot surface
exposure warnings.
For first aid contact your medical / safety representing.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 8 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Safety Instructions
Danger of Material Defects
Only approved and CE certied temperature controllers rated for application with
over current / voltage protection should be used with Hot Runner Systems.
Verify that all cables are damage free and in good condition.
Verify that all electrical connectors are clean and making good contact, and are
securely fastened and latched. Dirty or otherwise contaminated connector pins can
cause loss of signal and subsequent errors.
Clean all connectors with a spray-type commercial electrical contact cleaner /
degreaser and allow them to dry fully before reconnecting.
All Synventive Hot Runner Systems shall be tted with a temperature controller
to provide separate temperature adjustment for each heating zone; the controller
shall have the Soft-Start function for gradual heat-up. In this way you can prevent
premature wearing and damage to the hot runner system.
To extend the lifetime of temperature sensors, avoid long-term operation of
temperature control in manual mode.
Immediately replace defective temperature sensors.
If you replace heaters or their parts, always use original spare parts from
Synventive and carry out the replacement as described in this manual.
Do not interchange power supply cables with temperature sensor cables.
Temperature sensor cables are not suitable for high voltage applications and will
melt if exposed to high currents. Power supply cables are not suitable for use as
temperature sensor cables for data transfer to the temperature controller.
To maximize the life of temperature sensors, maintain the operating temperature
as specied in the respective material safety data sheets during processing.
Take notice of the production and color identication of temperature sensor cables.
Always use the specied temperature sensor.
Check that the aluminum surfaces of heaters do not come in contact to the nozzle
cut-outs. If they do, enlarge the nozzle cut-outs as needed. Any contact between
the heaters and the nozzle cut-outs will lead to the risk of improper temperature
control, which could result in damage to the aluminum casting.
If applicable, set the necessary operating temperature to the lowest level possible
to avoid plastic degradation and to prevent damage to the temperature sensors.
The cooling compound for nozzles with a cooling insert should always have the
correct mixing ratio to prevent corrosion and obstructed circulation.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

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Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 9 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Service and Maintenance / Pre-Installation
2 Pre-Installation
2.1 Injection Molding Machine Interface
2.1.1 General Safety Instructions for the eGate® Controller
Installation and Wiring Instructions
Read all safety instructions.
●Failure to comply with the instructions may cause serious injury.
●All safety instructions shall be carefully studied before the operation of the Synventive eGate® Controller system
is launched. The eGate® contains static sensitive components that can be damaged by incorrect handling. It
is expected these products will be protected from hazardous or conductive materials and/or environments that
could cause harm to the unit by damaging components or causing electrical shorts. It is important to protect
these items from excessive or corrosive moisture, abnormal ambient temperatures, and conductive materials.
Danger to Life by Electric Shock
The electrical cables connected to the eGate® Controller System, Injection
Molding Machine and Hot-Runner are under high voltage.
Serious personal injury or death can result from electrical contact.
Electrical work must be carried out by qualied persons.
Verify that all power source connections are properly grounded.
In Emergency case - Switch all systems off.
For first aid contact your medical / safety representing.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12

EN
CP
TA
Synventive Molding Solutions eGate® Instruction Manual SVC-17-0021_EN-Rev1.0
Current version at www.synventive.com - 10 - © 2012 All rights reserved
Master Language is English Errors and omissions excepted
Service and Maintenance / Pre-Installation
Mandatory
Safety
instructions
Danger of Personal Injury
When unpacking the eGate® Controller system, there is a risk of injury due to
falling parts and sharp edges. Handle equipment with care.
Transport and lifting equipment should be operated only by trained personnel.
Only approved and CE certied temperature controllers rated for application with
over current / voltage protection should be used with Synventive eGate® Hot
Runner Systems.
Only trained personnel shall have access in danger zones and access to electrical
enclosure.
When replacing fuses of the eGate® Controller, switch power to the system to the
“Off” position via the rear Power Switch.
Before connecting or disconnecting any cables switch “Off” the rear Power switch
to the unit; Cables in the eGate® system and the injection mold interfaces may still
be energized.
Failure to do so may lead to damage of the eGate® system or injury to
personnel.
Electrical terminals for attaching cables in the eGate® system shall never come
into contact with the coolant or hydraulic uid.
They could be short-circuited or a fire could occur, leading also to damage
of the eGate® system or injury to personnel.
Electrical terminals for attaching cables in the eGate® system shall never come
into contact with the coolant or hydraulic uid.
They could be short-circuited or a fire could occur, leading also to damage
of the eGate® system or injury to personnel.
End-User System must provide both an “E-Stop” and a Safety Gates Opened
interlock to disable the interface between the eGate® Controller and the Injection
Molding Machine.
The electrical power cord must be detached from the eGate® Controller unit and
in “line of sight” of the service personnel whenever the top panel cover has been
removed.
An appropriate CE rated and approved power cord for the native country must be
attached to the Synventive eGate® for proper operation and safety.
Failure to do so may cause damage to the controller unit or may be harmful
to personnel.
When more than two eGate®Controller’s are stacked, Synventive recommends
utilizing a 19”-2U open-rack frame and the side fans must not be blocked.
Blockage of the fans may lead to damage of the eGate® system, fire or
injury to personnel.
Extract of SVC-17-0021_EN-REV1-0 - PRE-Installation
2012-10-12