DME Company

DME Company
VCTH-4000, 8000
Four Zone and Eight Zone
Timer Based Hydraulic
Valve Gate Controller
User Manual
D-M-E Company
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 1
SAFETY
D-M-E Company products have been designed to be safe and simple to operate. As with
any electronic equipment and hot runner system, you must observe standard safety procedures to protect both yourself and the equipment.
To Prevent Injuries:
• To avoid electrical shock or fire hazard, do not apply voltage to a terminal that exceeds
the range specified for that terminal.
•
To avoid mechanical injury, electrical shock or fire hazard, do not operate this product
with covers or panels removed.
•
To avoid electrical shock or fire hazard, do not operate this product when wet.
•
To avoid injury or fire hazard, do not operate this product in an explosive atmosphere.
•
To avoid burn hazards, do not operate valve gates with operator gates open. Correct
hookup of valve gates should only be performed with all operator guards in place.
•
To avoid burn hazards and possible damage to equipment, do not leave hot runner systems at elevated temperature for extended periods of time. When the mold and machine
are not operating, disconnect the molding machines injection unit from the hot runner
system so that pressure may discharge through the sprue or manifold extension nozzle.
Make sure the molding machines purge guard is in place.
•
DO NOT look into the hot runner system when actuating the valve gates with the HAND
position. Serious burns could occur. The molding machine gate should be closed when
ever operating a valve gate.
To Prevent Product Damage:
• Do not operate this product from a power source that applies more than the voltage
specified.
•
Do not apply any external voltage to the injection forward input. Only a contact closure or
solid state relay should be used as an input.
•
Set hydraulic operating pressure before connection to the valve gate system. The system is capable of generating ten times the connected air pressure which could be higher
than the recommended operating pressure of the valve gate system.
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 2
DME RIGHTS
Copyright © D-M-E Company 2005. All rights reserved.
D-M-E Company products are covered by USA and foreign patents, issued and pending.
Information in this publication supersedes that in all previously published material. Specifications and any changes are reserved.
D-M-E Company and D-M-E are registered trademarks of D-M-E Company.
Printed in the United States of America
D-M-E Company
29111 Stephenson Highway
Madison Heights, MI 48071
WARRANTY
D-M-E Company warrants that this product will be free from defects in materials and workmanship for a period of one (1) year from the date of shipment. If any such product proves
defective during this warranty period, D-M-E Company, at its option, either will repair the defective product without charge for parts and labor, or will provide a replacement in exchange
for the defective product.
This warranty shall not apply to any defect, failure or damage caused by improper use or
improper or inadequate maintenance and care. D-M-E Company shall not be obligated to
furnish service under this warranty a) to repair damage resulting from attempts by personnel
other than D-M-E Company representatives to repair or service the product; b) to repair damage resulting from improper use or connection to incompatible equipment; or c) to service a
product that has been modified or integrated with other products when the effect of such
modification or integration increases the time or difficulty of servicing the product.
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 3
VCTH-4000, VCTH-8000
Four and Eight Zone Timer Based
Hydraulic Valve Gate Controllers
for flow. A hydraulic accumulator provides
instantaneous flow for fast actuation of
This manual describes the installation, hydraulic cylinders.
operation and servicing of the Valve Gate
The hydraulic system is capable of providing
Controller.
up to ten times the incoming air pressure. For
The VCTH-4000 provides four zones of example, if air pressure is 100 PSI, the
hydraulic actuation. The VCTH-8000 provides hydraulic system is capable of delivering
1000 PSI. An air pressure regulator allows for
eight zones of actuation.
adjusting the desired hydraulic pressure
The Controller uses DIN style solid state
timers to provide long life and high reliability. UNPACKING AND INSPECTION
Each timer is capable of dual time functions
so that each zone can be programmed with a After unpacking, inspect your controller and
delay time (timer 1) and an on time (timer 2). check for any damage that may have
The timers in turn drive larger solid state occurred during shipment.
relays that are individually fused against
faults.
Check for proper operation of power switch
by turning the switch on and off with no
The Controller is designed to operate from a voltage applied. Check all electrical
wide supply of operating voltages (88 to 264 connectors for visual damage. If any damage
Volts AC) so that this one device can be used is observed, return the controller to D-M-E for
with almost any available power source. This repair or replacement.
also makes it easier to relocate the controller
between different plants or even different INSTALLATION
countries. The standard product offering
comes with a 125 volt AC plug (North You are installing a piece of electronic
American Standard). This plug may be equipment, which should not be subjected to
removed and replaced with any number of any physical or environmental abuse. Select
240 VAC plugs.
a cool, dry, well-ventilated, environmentally
clean location, away from heat and moisture.
Test functions are available for each zone to
assist in determining the correct hookup of Connection of Trigger Signal
each of the valves.
Using the cable supplied with the controller,
Hydraulic connections on the back of the connect the controller to the injection molding
controller allow for quick connect and machine. The best way to accomplish this is
disconnect of the hydraulic lines from the to supply a dry contact (relay contact closure)
controller.
that is triggered by the injection forward
signal of the molding machine. A solid state
An air powered pump prevents potential relay contact can be also be used. It should
burning of oil which is a typical problem with source power from contact A to contact C.
variable volume piston pumps. The air
powered pump also saves electrical energy
as the pump only runs when there is demand
GENERAL DESCRIPTION
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 4
Alternatively, a limit switch that is operated
from mold closure can be used as the trigger
signal. The limit switch can be mounted to
the tie bar to catch the closing of the moving
half of the mold. It may also be mounted to
the mold to detect contact of the mold halves.
Contact B of the connector supplies a ground
signal to provide shielding of the cable
assembly.
Red
Black
Shield
A
C
Use the SET/LOCK button on the front of the
timer to select between the delay timer
(Timer 1) and the on timer (Timer 2). The
Timer unit front panel will display which timer
is selected. (See Page 11).
Use the up and down arrow buttons below
the display to set the desired time value.
Each time value can be set to any value
between 00.00 seconds to 99.99 seconds. To
set any valve to open immediately, set the
delay timer (Timer 1) value to 00.00 seconds.
If the sum of the delay and the on timer is set
to a value larger than the time the trigger
signal is active, internal electronics will
automatically reset the timers at the end of
the trigger signal.
B
Trigger Signal Connection
Connection of AC Power to Controller
When triggered, “Timer 1” (delay timer) of
each of the timers will be displayed. The
timer will count down until it reaches zero.
When Timer 1 reaches zero, Timer 2 (on
timer) will be displayed and the timer will
count down until it reaches zero. If Timer 1
value is zero, Timer 2 will be displayed when
the trigger signal is displayed, Timer 1 will not
be displayed.
The standard offering of the controller is
provided with a 120 VAC connector. The
controller is designed to run from any voltage
between 88 VAC and 264 VAC. Connect the
brown conductor of the power cable to L1 (or
hot), the blue conductor to L2 (or neutral) and
the green conductor with the yellow stripe to
ground. Do not operate the controller without Proper setting of each of the “on” timers is
determined by part weight or size. For most
the ground conductor connected.
applications, the on timer should run through
NOTE:
ALL NATIONAL AND LOCAL the injection fill phase and into the pack (and
EL E CT R I C AL
CO D ES
M U ST
B E hold, if present) phases of the injection
FOLLOWED WHEN CONNECTING THIS molding machine.
EQUIPMENT.
In order for the timers to function, the related
selector switch must be in the AUTO position.
OPERATION
NOTE: The timers do not run in the OFF or
Timer Setup
HAND position.
Do not perform this step until all electrical
connections are performed.
WARNING!
Turn controller power on. The timer displays
should illuminate. If they do not illuminate, Do not operate the HAND function of the
see the Maintenance and Repair sections selector switches when someone is inside the
gate area, especially if they are looking at the
below.
face of the hot runner system.
Each timer unit has two internal timers. Timer
1 sets the delay from when the trigger signal When manually testing valve gate operation,
is received and the valve is to open. This is make sure the safety gate is closed. Failure
referred to as the “delay” timer. Timer 2 sets to do so could result in serious injury.
the duration the valve is open. This is
referred to as the “on” timer.
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 5
of the air regulator up and turn it to achieve
the desired hydraulic pressure. If hydraulic
pressure is higher than required, adjust the
air regulator to 1/10th of the desired hydraulic
pressure. Use the HAND position for valve
gate #1 to reduce the built up hydraulic
pressure in the system. Continue making
Verify correct operation of the timers once the adjustments until the desired pressure is
obtained.
trigger signal is applied.
The HAND position of the selector switches
can be used to verify correct connection to
the valve gates. Warning!: verification
should be performed with the operator
gates closed to prevent injury from hot
plastic.
Fill the Hydraulic Reservoir
The hydraulic system is compatible with a
large range of hydraulic fluids. In the absence
of information regarding the valve gate
system, Mobil DTE 25 or an equivalent is
recommended. This has an ISO Grade of 46.
Hydraulic
Pressure
Gauge
Air Pressure
Adjustment
Knob
After making sure that the empty port on the
front of the unit is tight, fill the reservoir to the
top of the sight glass. Once the hydraulic
connection lines are charged the first time, it
may be necessary to add more hydraulic
fluid.
Connect Air Pressure Supply
Connect an air line to the back of the unit.
Quick connects are not recommended as
they will limit air volume. Maximum
recommended air pressure is 100 PSI. If the
system is to run near continuously, it may
require upwards 50 CFM of air flow.
Air Pressure
Gauge
Disconnect the hydraulic line looping the
A dry air supply is recommended. While the open and closed ports for valve gate #1.
pump is capable of handling moist air, water
may be build up inside of the cabinet and Alarms
leak onto the floor.
The system is equipped with a high oil temperature sensor and a low oil level sensor. If
Setting Hydraulic Pressure
either of these activate, an alarm buzzer will
Hydraulic pressure should be set prior to activate and the appropriate light on the top
connection to the valve gate system. of the controller will illuminate.
Maximum hydraulic pressure will be ten times
If the alarm activates, shut the system down
the available air pressure.
immediately. Overheating of oil could be an
Connect one of the supplied hydraulic lines to indication that mold cooling of the clamp plate
the open and closed connections for valve is not in place. The over temperature alarm
triggers at 150 +/- 10 °F (65.5 +/- 5.5 °C). The
gate #1.
low oil level will alarm will trigger when oil
Turn controller power on. The pump will run falls below approximately 3.8 gallons (14.4
liters).
until the accumulator is charged.
Open the bottom door of the cabinet. There is An optional clogged oil filter alarm may also
an air pressure gauge and a hydraulic be present on the system.
pressure gauge. Note the hydraulic pressure.
To adjust the hydraulic pressure, pull the top
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 6
disconnect the cable from the controller and
ensure the molding machine provides a
NOTE: DISCONNECT POWER BEFORE contact closure when expected by checking
SERVICING. ONLY ELECTRICIANS OR the signal between pins A and C.
TRAINED SERVICE PERSONNEL SHOULD
REMOVE ACCESS PANELS TO SERVICE If you can see a contact closure between pins
A and C. You can also check for the
INTERNAL COMPONENTS.
presence of 24 volts DC between pins A and
C of the trigger signal connector on the back
Periodic Maintenance
of the unit.
At the rear right inside the lower part of the
unit, there is a clogged filter indicator. When Timer(s) Run But Valve(s) Don’t Open
the unit is running (pumping), check the
gauge. The gauge should be in the green Check the small fuses on top of the internal
range. If it is in the red range, the filter is in solid state relays for continuity. If any of these
fuses are determined to be open, check the
need of replacement.
affected zone valve for a short circuit.
Replace defective fuses only after
determining that the related valves are in
good order.
MAINTENANCE AND REPAIR
If the fuses on top of the solid state relays are
good, it is possible that a solid state relay
may require replacement. Replacement fuses
and relays are available from DME. See page
Also periodically inspect and clean the fan 11.
and breather filters on the rear of the unit.
Timer Replacement
Hydraulic oil quality should be periodically
If timer replacement appears to be
checked, as well.
necessary, we recommend returning the unit
to DME or have it serviced by another known
Troubleshooting and Repairs
qualified service technician. Replacement
timers are available from DME. Use part
Timers Do Not Illuminate
number RPM-0100.
Make sure controller is plugged in and that
outlet power is on. Some molding machine The replacement timer must be setup before
outlets may not be energized if machine installation. (See Page 11). A small access
plate on the right side of the timer gives
power is off.
access to a bank of small switches. Open the
If controller is plugged in and outlet has plate. Set all switches except switch number
power, check the fuses inside the top of the four to “ON”. Replace the damaged timer
controller. Use only the fuses identified in the making sure to locate all wires in the proper
location. Tighten all unused screws. The
replacement part list on page 11.
provided instructions also give details on
If a single timer does not illuminate, it may correct mounting of the timer.
require replacement. See timer replacement
at the end of this section. The timers are The first time the unit is powered up, set the
designed to operate for 10 million cycles so timer to “Integrate A” mode by performing the
they should not require replacement very following: (1) Press and hold the SET/LOCK
button, (2) Press the right most up or down
often.
arrow, (3) Release the SET/LOCK button, (4)
Continue pressing the right most up or down
Timers Illuminate But Don’t Run
arrow until “In-A” is displayed, (5) Press the
Check the trigger signal cable and make sure reset key. The timer is now ready for use.
it is connected. If the cable is connected,
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 7
SELECTOR SWITCHES
AUTO / OFF / HAND
(HAND = MANUAL)
TIMERS
LOW OIL LEVEL
ALARM LIGHT
HIGH OIL TEMPERATURE
ALARM LIGHT
POWER
SWITCH
CONTROL PANEL OF UNIT
SWITCHING
POWER SUPPLY
SOLID STATE RELAYS
AND FUSES
(FUSES ON TOP)
TRIGGER SIGNAL AND
ALARM PROCESSING
CIRCUIT BOARDS
INTERNAL ELECTRONICS
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 8
AC POWER
FUSES
AC POWER
DISTRIBUTION
BLOCK
DC POWER
AND GROUND
DISTRIBUTION
POWER FUSING AND DISTRIBUTION
TRIGGER INPUT
(Injection forward
or mold close)
WARNING!
DO NOT INJECT
AN EXTERNAL
VOLTAGE INTO
THIS INPUT!
AC POWER
INPUT
HYDRAULIC
CONNECTIONS
(OPEN ON TOP,
CLOSED ON
BOTTOM)
AIR INPUT (Do not
use quick connects)
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 9
SPECIFICATIONS
ELECTRICAL
HYDRAULIC
Hydraulic Pump
5 Gallon/Min. (18.9 Liters/Min.)
Air powered
30 — 100 PSI (2.07— 6.89 BAR)
Max volume: 50 CFM (1416 Liters/Min.)
10:1 Intensification ratio
(60 PSI air yields 600 PSI hydraulic)
AC Power Input
120 or 240 VAC, 50 or 60 Hz
Actual range, 88 to 264 VAC
Accumulator
1 Gallon (3.79 Liters)
With discharge valve
Depressurizes when power is off
Precharged with 400 PSI Nitrogen
Power Supply — 24 VDC
VCTH-4000: 300 Watt
VCTH-8000: 500 Watt
Main Circuit Protection
VCTH-4000: ABC-5 fuses (2)
VCTH-8000: ABC-10 fuses (2)
Solid State Relays
3 amp, 60 VDC relays
4 in VCTH-4000
8 in VCTH-8000
Protected by 4 amp fuses
Spare fuse(s) included
Valves
D03 Form Factor
24 VDC Coils
Single solenoid, spring return
Four or eight valves
Hydraulic Quick Connects
HNV-14-M by PCI
Similar to Parker 60 Series
Air Regulator
Adjustable zero to 100%
Set to adjust hydraulic pressure
Alarm Sensors
Oil Temperature
Triggers at 150 +/- 10 °F
(65.5 +/- 5.5 °C)
Oil Level
Triggers at under 3.8 Gallons (14.4 liters)
There may be an optional clogged filter
alarm, as well.
D-M-E Company
VCTH-4000, 8000
ED-0117-OT-004-A
Page 10
TIMERS
Use SET/LOCK button to change between
T1 (delay) and T2 (on) timers. Use up and
down arrows to change time values
RETURN POLICY
The D-M-E® VCTH-4000™ and VCTH-8000™ are warranted
for 1-year parts and labor, excluding fuses. Contact D-M-E
Customer Service for return authorization for repairs, or warranties. Replacement parts are also available through the Customer Service Department.
D-M-E Customer Service
In U.S.:
1-800-626-6653
In Canada:
1-905-677-6370
SERVICE CENTER U.S.A.
D-M-E WORLD HEADQUARTERS
29111 STEPHENSON HIGHWAY
MADISON HEIGHTS, MICHIGAN 48071
TELEFAX: (248) 398-6174
D-M-E® is a registered trademark of D-M-E Company.
D-M-E Company
TIMER SETUP
Set all switches except 4 to ON (as
shown). Switches are on right side of
timer behind a cover plate
REPLACEMENT PARTS
DESCRIPTION
Fuses
VCTH-4000
VCTH-8000
Solid State Relay Fuses
(T5 series, 4 amp, 250
VAC)
Solid State Relay
CATALOG
NUMBER
ABC-5
ABC-10
RPM-0098
RPM-0099
Replacement Timer
RPM-0100
Trigger Cable
RPM-0101
VCTH-4000, 8000
ED-0117-OT-004-A
Page 11
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