The G24 Temperature Controller - Gammaflux

ControlThe G24Temperature Controller

Easier to Use (New Mold Wizard)Best industry practices and actual operationare often not the same. The G24 is designed tobe understood with 5 minutes of training, andprogrammable to automatically operate accordingto the industry’s best practices. The GammafluxNew Mold Wizard effortlessly guides the userthrough (1) zone identification and groupcreation, (2) setpoint entry, (3) monitor zoneconfiguration, (4) sophisticated mold startupfunctions, (5) advanced zone monitor functions,(6) heating the mold and (7) saving the menu.During this process the software automaticallytunes each zone, engages the plastic leak detectionalarm, sets the imminent heater failure alarmand saves everything back to the mold menuautomatically after the “good parts” button isconfirmed by the operator. The Wizard makeseveryone a controller configuration expert.Less ExpensiveBy leveraging the global electronics supply chainwith new components that take the place ofmultiple previous components, Gammaflux hasbeen able to reduce the price of the G24 productline in relation to existing Gammaflux products.Gammaflux, long known as the reliabilityand control leader in the industry, combines acompetitive price with superior performance inthe G24 controller.SmallerEach control module has a 15 or 30 amp perzone output rating. Up to 24 zones can be placedin a single control block. When compared to theGammaflux TTC product line, this specific128 zone controller has a 48% smaller footprint.128 zones96 cavityDelta: 150 ampWye: 70 ampWidth: 20in / 50.8cmDepth: 23in / 58.4cmHeight: 50.25in / 127.6cmFasterThe G24 utilizes industrial USB connectivity for up to a 0.1 secondscreen update rate. Streaming real-time control numbers to the screenallows the user to better see what is happening inside the tool so theycan diagnose difficult to understand issues.More Flexible/StandardizationThe standard two zone 15 amp per zone output module easilycontrols both tip and manifold zones making the controller easyto use across a range of molds for effortless production scheduling.The G24 is even able to control up to 30 amp zones with a 15 ampmodule by restricting the maximum output to 15 amps using ourRMS limiting feature. Standardizing with Gammaflux allows youto pick the best manifold supplier for your specific application.Choosing a combined controller/manifold package will inevitablyresult in multiple control brands to support and learn.Improved InterlocksThe tools of today are far more sophisticated and sensitive thanthe tools of yesteryear. Machine interlocks ensure bad parts are notproduced and catastrophic damage is avoided. The G24 makes theinterlocking task easier than ever with on-screen interlock signalinversion and manual testing signals to speed setup.Mold Doctor ®Automate your mold troubleshooting with Mold Doctor® . Elusiveproblems that appear suddenly and without changes to the processcan be diagnosed with a quantitative thermodynamic zone analysis.Early Leak DetectionWhen material/plastic leaks into the mold it occupies a former airspace. Eliminating the air space creates a heat sink to the surroundingmass. In automatic mode, the controller increases the power tocompensate for the loss in heat. The New Mold Wizard automaticallysets the watt baseline and engages the alarm after the “good parts”part button is confirmed by the operator. Precisely measuring theactual wattage can be the difference between a short trip to the toolroom or weeks of lost production.5 Year Warranty*Every G24 controllercomes with a full5-year warranty andis backed by theindustry-leadingworldwide serviceand support that ourcustomers expect fromGammaflux.Easy to Use* 2 year warranty on thetouch screen interface

Standard ConfigurationsOverviewControl BlocksHalf size control block12 zones (15 amp per zone)Maximum zones and circuit breakershown for each enclosureM12 zonesDelta: 50 ampWye: 30 ampT124 zonesDelta: 100 ampWye: 60 ampControl BlocksFull size control block24 zones (15 amp per zone) or6 zones (30 amp per zone)Maximum zones and circuit breakershown for each enclosureT124 zonesDelta: 150 ampWye: 80 ampOptionsRemote Mount Touch Screen21 feet, 6.4 meters or 42 feet, 12.8 metersDaisy ChainLink multiple enclosuresT248 zonesDelta: 100 ampWye: 60 ampT248 zonesDelta: 200 ampWye: 100 ampMS12 zonesDelta: 50 ampWye: 30 ampS124 zonesDelta: 100 ampWye: 60 ampS248 zonesDelta: 100 ampWye: 60 ampS248 zonesDelta: 200 ampWye: 100 ampS372 zonesDelta: 200 ampWye: 100 ampStandard Circuit BreakersEnclosure 30 50 60 70 80 100 125 150 200 250 300M or MS D or W DeltaS or T short top D or W D or W Wye Delta DeltaS1 or T1 tall top D or W Wye Delta Wye Delta Delta DeltaS2, S3 or T2 tall top D or W Wye Delta Wye D or W Delta Delta DeltaD tall top D or W Wye D or W D or W D or W D or W D or W Delta Delta

Machine MountCompatible EnclosuresT1, T2, T3 and T4Cable HangerCable HangerThe optional cable hanger can be added toany G24 controller. Constructed of steelthis durable double sided cable holdereases controller storage and transport.D296 zonesDelta: 300 ampWye: 200 ampD3144 zonesDelta: 300 ampWye: 200 ampTransformersD4192 zonesDelta: 300 ampWye: 200 ampTransformersOptional 480 VAC to 240 VAC Delta/Delta three phase 2:1 step downtransformers are available. The smaller transformer pod can contain a 15,30 or 45 kva transformer. The larger transformer pod can contain a 75 or112 kva transformer. Each transformer pod is detachable, has forced aircooling and an independent circuit breaker.Overview

New Mold WizardWizardLaunch31LearnProtect2Set5Predict4Program7Save6HeatConfirm Save

Mold Doctor ®Troubleshoot Your MoldMold Doctor® is an off-line (tool room), advanced troubleshootingtool consisting of four diagnostic tests:Wiring Analysis: checks the wiring of the tool. The softwareclearly tells the user of miswired zones and how to fix them.Fault Analysis: quickly identifies the following problems:thermocouple open, thermocouple reversed, thermocouplepinched, open fuse, heater short/wet, heater open,uncontrolled output and ground fault.Thermodynamic Analysis: automatically heats allselected zones to 400º F (204º C) and cools to 330º F(165º C). During the heating and cooling processMold Doctor® records critical information and reportsto the user. Compare like zones against one another;major differences in the four key areas (resistance, powerconsumption, heating and cooling rates) will point youtowards a solution. Once the tool is qualified, save athermodynamic analysis as your known “good parts”baseline. Future problems will be easy to diagnose using thehistorical mold performance tool.Historical Mold Performance: allows the user to easilycompare a known “good” thermodynamic analysis baseline to thecurrent “suspect” thermodynamic analysis. Intuitively troubleshootyour mold with hard data.Mold Doctor ®CalibrationCalibrate your controllers in house quickly, easily and without acalibration technician. Establish a thermocouple source equivalentto the controller. The difference between the calibrator value andthe control screen is the calibration error. The Calibration softwarecorrects the error with an accuracy of ± 0.2º F (± 0.1º C).

Faster (0.1 sec Screen Updates)FasterGammavision ®Gammavision® chart recorderand statistical analysis softwareallows the user to record theperformance of their hot runnertool, print reports to the USBdrive or watch databases ofproduction runs on-screen withour playback mode. Pause liveaction on the line graph andmanually or automatically placeinjection marks on the screenfor in-depth analysis.[InjectionMark][Paused]Cavity Map Pro Cavity Map Pro Quickly create a cavity mapthat is saved with the moldmenu. The on-screen toolsallow the user to createcommon tip layout patternsinstantly. Select zones to studycloser and flip the image toquickly identify which zone/cavity to change or investigate.

“Lights Out” MoldingImproved InterlocksThe tools of today are farmore sophisticated andsensitive than the tools ofyesteryear. Machine interlocksensure bad parts are notproduced and catastrophicdamage is avoided. TheG24 makes the interlockingtask easier than ever withon-screen interlock signalinversion and manual testingsignals to speed setup.Early Leak DetectionInterlocksLeak DetectionExample PictureThe photo to the right is a pictureof an actual leak that was detectedearly by the Gammaflux watt/leakalarm. As you can see the materialstarted leaking out the backside ofthe tip but did not make it to thewires. Once the wires are coatedin plastic the heater, thermocoupleor both will need to be replaced.Detecting leaks early not onlysaves money but also speeds themold back into service.Actual Leak Detected with AlarmToo Late – Example

Detailed Controller ComparisonNext GenerationTouch Screen ChoiceLEC TTC G24 G24Mini FullCore DescriptionTemperature control n n n nTemperature control - maximum zones 24 280 48 480Sequential valve gate control - integrated optionnSequential valve gate control - outputs 8/16/325 year warranty (2 years on touch screen interface) n n n nModular design n n n nController warm up time - instant n n n nIf interface fails – the controller still controls n n n nEmergency interface - use a Windows® computer XP XP XP or 7 XP or 7Automatic/manual control n n n nZone “on”, “off” and “locked off” n n n nSet points in tenths n n nAdaptive PID 2 control algorithm with Power Priority® n n n nAlgorithm is executed 20 times per second n n n nExtended tuning ranges (fast/slow) n n n nOutput resolution 0.1% n n n nOutput attenuation - maximum output (1% increments) n nRMS limit to module max. - control larger heaters n nPhase angle firing (1000 Steps; 0.1%) n n n nWet heater bakeout n n n nPower compensation in manual mode n n n nDegree F/C n n n nThermocouple J/K n n n nThermocouple (T/C) filtering - none n n n nT/C resolution 0.03 o F (0.014 o C) over full scale n n n nT/C calibration accuracy 0.2 o F (0.1 o C) over full scale n n n nOperating temperature 32-122 o F (0-50 o C) n n n nInput power 180-265 VAC; 480 VAC optional n n n nDelta/wye convertible option n n n nCircuit breaker sized to load - TTC/G24 - 300 amp maximum n n n nActual ValuesActual temperature n n n n% Output n n n nDeviation from set point n n nAmps (resolution 0.01 amps) n n n nVolts n n nWatts n n nKilowatt monitor (instant, average, max., min.)nOhms n n nAlarms(+) High temperature (adjustable; 20º F [10º C] default) n n n n(-) Low temperature (adjustable; 20º F [10º C] default) n n n nThermocouple open (remembered % output) n n n nThermocouple reversed n n n nThermocouple pinched (adjustable time) n n n nOpen fuse n n n nShorted heater/wet n n n nProgrammable heater short threshold (amps) n nOpen heater n n n nUncontrolled output (relay power cut off) n n n nHeater resistance monitoring (predict failure) n n nHeater wattage monitoring (detect leaks) - auto calc. n n nGround fault detection n nCritical over temperature alarm (adjustable) n n n nTemperature monitoring (J/K) with programmable action n n nAlarm history - zone alarms n n nAlarm history graph - zone alarmsnZone alarm configure - “none”, “flasher”, “flasher & contacts” n nAlarm history - system and status n n

Touch Screen ChoiceLEC TTC G24 G24Mini FullOperational FeaturesMenu storage 1000+ 40 1000+Menu “auto save” (optional)nProgrammable groups n n nInstant grouping n n nSequence Start (up to 4 stages with delay timers) n n nSequence Cool (up to 4 stages with delay timers) n nSequenced Power Up - manual activation n n nBoost (selectable time/amount) - Automatic mode n n n nBoost (selectable time/amount) - Manual mode n nTrim n n nEven Heat (controlled heating - 20 o F [10 o C] max. variance) n n n nEven Cool (controlled cooling - 15 o F [7 o C] max. variance) n n nAutomatic set point limit n n n nManual set point limit n n n nSecurity levels n n n nSecurity level customization (4 levels)nOn power up “on” or “off” (“ask” touch screen only) n n n nAuto load manual remembered % output n n nOperator identification n nTool graphics with real time data overlay n nCavity Map Pro® with “mirror” buttonnThermocouple “rewire” n n nCopy Output n n nStandby timer until system “off” n n nPDF writer n n nPDF viewer - import or export files n nUSB port n n nOn-line help n n nSoftware FeaturesNew Mold Wizard n nMaximum screen update rate (in seconds) 6 0.5 1 0.1E-Z Screen - 5 minutes to train n nGammavision® (SPC data/graphing) n nPause line graph with “injection marks” (manual and automatic)nInstant data reporting (hours) / 24 24 24 48Data report storage (up to 1 year) - pdf format n nMold Doctor® (advanced troubleshooting) n n nCalibration (0.2 o F [0.1 o C] accuracy over full scale) n n nOn screen printing n n nPrint to USB drive n nNetworking (Ethernet IP) - stream .csv file - bidirectional n n nRemote troubleshooting/operation n nField software identification of enclosure connectors and pinsnTime and date change during operation n nTouch screen calibration during operation n nOn-screen keyboard for Windows® tasks Find this module LED n nn n nDaisy chain enclosures n n n nInputs (24 VDC required)Standby n n n nMaterial protection n n nInhibit/Allow n n n nSequence Start n nSequenced power up n n nRemote boost n n nMold ID - 63 combinations - auto menu load n nSequence Cool n nEven Cool n nWater flow interface n nChiller interface n nBarrel temperature interface n nDryer interface n nAuxiliary interface n nExternal manifold leak detect (Airtect) n nOutputsResettable alarm output n n n nNon-resettable alarm output n n n“OK to Run” output with status page n n nAudible alarm n n nManual activation/deactivation to speed interlock setup n nLimited featureTouch screen or laptop required (LEC)Windows XP® and Windows 7® are registered trademarks of Microsoft CorporationNext Generation

PerformanceThermocouple Calibration AccuracyControl Accuracy (steady state)Heater Short Detection TimePID 2 Alogrithm Execution TimeTuningManual ModeDegrees F or COperating RangeOutput RangeStandby TemperatureRemote InputInputThermocoupleCold Junction CompensationExternal ResistanceTemp. Variation due to T/C Length0.2°F (0.1°C)± 0.1°F (± 0.05°C)8.3 msec. or 120 times per second at 60 Hz50 msec. or 20 times per secondAutomatic, self optimizing, manual overridePower compensation for incoming voltage variationField Selectable0-932°F (0-500°C)0-240 VAC, Phase angle fired,1000 stepsUser Selectable (0-932°F, 0-500°C)24 VDCType J standard; Type K selectableInternal to enclosure10 Meg. OhmsNoneElectricalInput Voltage180-265 VAC Delta/Wye (phase voltage)Frequency47-53 Hz, 57-63 HzAmbient Temperature Range32-122°F (0-50°C)Humidity Range10-95% non-condensingOutput Module Rating240 VAC; 2 zone - 15 amps/zone 3600 watts/zone240 VAC; 1 zone - 30 amps/zone 7200 watts/zoneCommunications Electrical Standard Industrial USB 2.0Performance StandardsU.S., Canadian and International: CE Mark; EMC: IEC 61000 - (6-2, 6-4, 4-2, 4-3, 4-4, 4-5, 4-6, 4-11)*Designed to meetSafety* IEC 61010, UL-508, UL-873 and CSALanguagesVersion 4.0EnglishEnglish, Deutsch, Français, Czech, русский, Italiano, Español, Portuguese,Physical*Height Width Depth *Weight(inches/millimeters) (inches/millimeters) (inches/millimeters) (pounds/kilograms)M enclosure 20.00/508 10.00/254 12.50/318 50.0/22.7MS enclosure 36.50/927 23.00/584 20.00/508 75.1/34.1T1 enclosure - short top 21.25/540 10.00/254 23.00/584 75.1/34.1T1 enclosure - tall top 25.75/654 10.00/254 23.00/584 80.1/36.3T2 enclosure - short top 32.00/813 10.00/254 23.00/584 130.4/59.1T2 enclosure - tall top 36.50/927 10.00/254 23.00/584 135.4/61.4S1/S2 enclosure - short top 35.00/889 20.00/508 23.00/584 139.4/63.2S1/S2 enclosure - tall top 39.50/1003 20.00/508 23.00/584 144.4/65.5S3 enclosure - tall top 50.25/1276 20.00/508 23.00/584 199.7/90.6D2 enclosure - tall top 39.50/1003 20.00/508 23.00/584 243.6/110.5D3 enclosure - tall top 50.25/1276 20.00/508 23.00/584 343.2/155.7D4 enclosure - tall top 61.00/1549 20.00/508 23.00/584 442.8/200.9SpecificationsHeight and weight excludes screen.Specifications subject to change without notice.Global Headquarters* Gammaflux L. P.113 Executive DriveSterling, VA 20166 , USA) (800) 284-4477, or) +1-(703) 471-50507 +1-(703) 689-21318 info@gammaflux.comwww.gammaflux.comEuropean Headquarters* Gammaflux Europe GmbHBahnstrasse 9aD-65205 Wiesbaden-Erbenheim,Germany) +49-(0)-611-9734307 +49-(0)-611-97343258 info@gammaflux.dewww.gammaflux.deAsia-Pacific Headquarters* Gammaflux JapanYamaguchi, Ube, Japan) 7 +81-(836) 54-4369Gammaflux India) +91 99619228888 asia-pacific@gammaflux.com