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Husky UltraSync-E User Manual
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Husky UltraSync-E User Manual

Husky UltraSync-E User Manual

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UltraSync-E
User Guide
Original Instructions

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Summary of Contents for Husky UltraSync-E

  • Page 1 UltraSync-E User Guide Original Instructions...
  • Page 2 Husky® product or service names or logos referenced in these materials are trademarks of Husky Injection Molding Systems Ltd. and may be used by certain of its affiliated companies under license.

  • Page 3: General Information

    Husky Regional Service and Sales Office. Ordering Spare Parts All spare parts for Husky equipment can be ordered through the nearest Husky Parts Distribution Center or online at www.husky.co. Ordering Additional Manuals Additional copies of this manual and other documentation can be purchased through the nearest Husky Regional Service and Sales office.
  • Page 4 2.0 — March 2023 UltraSync-E Page iv...

  • Page 5: Table Of Contents

    Safety................8 UltraSync-E Controls, Connectors, and Parts Identification ..... . . 8 Initial Setup of the UltraSync-E.
  • Page 6 UltraSync-E Standalone System ........
  • Page 7 Calibrating the UltraSync-E ........
  • Page 8 — November 2021 UltraSync-E Page viii...

  • Page 9: Chapter 1 Introduction

    Altanium UltraSync-E (Electric) controller. It has the necessary information to connect the UltraSync-E to an Injection Molding Machine (IMM). Information to test hot runners with the UltraSync-E before the hot runners are installed on an IMM is also given.

  • Page 10: Safety Signs

    Follow all warnings and instructions marked on the system. • Unless specifically explained in this manual or directed by Husky, do not attempt to repair the system. Doing so could result in damage to the system, or serious personal injury.

  • Page 11: Purpose Of The Equipment

    Husky UltraSync-E hot runner. The UltraSync-E controller can have an optional temperature control function. Contact your nearest Husky Regional Service and Sales office if you plan to use a Husky product for anything other than its intended use.

  • Page 12: Input Wiring (Conventional)

    — March 2023 UltraSync-E Input Wiring (Conventional) The table that follows summarizes the wiring conventions used. Description Wire Color Neutral Blue Earth/Ground Green/Yellow Green Line Black Black Line Brown Line Gray White DANGER! Electrocution and/or mechanical hazard - risk of death or serious injury and possible damage to the equipment.

  • Page 13: Equipment Ratings

    — March 2023 UltraSync-E Equipment Ratings Ratings for the entire Altanium Controller can be found on the nameplate attached to the back of the controller. The following are the equipment ratings for the Altanium Delta5/Matrix5 operator interfaces: • Supply Voltage: 100 to 240 VAC ± 10%, single phase •...
  • Page 14 — March 2023 UltraSync-E Page 6...

  • Page 15: Chapter 2 Integration

    Know the molding cell fully, so that there are no dangerous procedures, installations, or connections. The system integrator must be supplied by the end user. Husky does not know all the necessary information for each customer and each molding cell.

  • Page 16: Safety

    UltraSync-E. Refer to Section 2.10 for lockout/tagout procedures. UltraSync-E Controls, Connectors, and Parts Identification Figure 2-1 shows the UltraSync-E and the location of the controls, connectors, and other parts on the UltraSync-E. Page 8...

  • Page 17: Initial Setup Of The Ultrasync-E

    Remove the material that stops the movement of the wheels. Lift the UltraSync-E from the pallet. Refer to Section 2.5.2. After you have put the UltraSync-E on a hard surface, the wheels of the UltraSync-E will let you push the UltraSync-E in position. Page 9...

  • Page 18: Lift The Ultrasync-E

    General WARNING! Only qualified, certified and trained personnel are permitted to lift the UltraSync-E. Injury to personnel and /or damage to the UltraSync-E can occur if you do not use the correct lifting procedures. The UltraSync-E has three configurations: •...
  • Page 19 — March 2023 UltraSync-E Bring the straps up and above the UltraSync-E controller and attach them to the lifting device. Refer to Figure 2-2. Figure 2-2 Straps and Lifting Device Make sure that the webbed straps go between the caster wheel and the retaining bracket.
  • Page 20 UltraSync-E cabinet. Refer to Figure 2-5. Figure 2-5 Cushioning Material Tighten the ratchet strap. With the lifting device, carefully and slowly lift the UltraSync-E stack 1 to 3 inches (25.4 to 76.2 mm). Page 12...

  • Page 21: Assemble The Ultrasync-E

    NOTE: The display module comes in a different protective box. With the front of the UltraSync-E in front of you, remove the four M6 x 1mm button head cap screws from the top of the UltraSync-E stack. Put the display module on top of the UltraSync-E and align the display module holes with the holes in the top of the UltraSync-E stack.

  • Page 22: Connect The Input Power

    Contact Husky customer support if it is necessary to change the power supply configuration. Overcurrent Protective Device The UltraSync-E has a main power switch on the front of the cabinet. Refer to Figure 2-1. The UltraSync-E does not have an input power overcurrent protective device.

  • Page 23: Bonding

    TN, TT, or IT system. 2.10 Lockout/Tagout Procedures If you do maintenance on the UltraSync-E, you must do lockout/tagout procedures. Use the main power switch on the UltraSync-E cabinet to de-energize the UltraSync-E and the IMM. Refer to Figure 2-1.

  • Page 24: Connecting The Controller

    Contact the nearest Husky Regional Service and Sales office for assistance. 2.12 Input/Output Signals and Other Connections On the back of the UltraSync-E are the connections for the input/output (I/O) signals, UltraSync-E servo motor, and EtherCAT. 2.12.1 Input/Output Signals An X100 interface connection is used to send input/output (I/O) signals between the UltraSync-E and the injection molding machine (IMM).

  • Page 25: X100 Connection

    IMM connectors. The system integrator must refer to the IMM electrical schematics and the UltraSync-E signal/pin descriptions to see how to connect the cable leads on the IMM connectors. The cable leads can also be hard wired directly to the IMM control cabinet.
  • Page 26 This signal is required when a EUROMAP 67 (EM67) or EUROMAP 12 (EM12) communication interface is used. The UltraSync-E operates as a “disengaged robot” to the IMM, if an EM67 is connect to the IMM. At a HIGH level, the part handling device is not engaged, thus the IMM does not need any other EM67 signals (for example, Permit Mold Close, Ejector forward/back).
  • Page 27 IMM movement. The signal must be isolated from all other signals. This signal is necessary for operation. 24VDC of Controller Reference HIGH level from the UltraSync-E, for relay outputs from the IMM. This signal is necessary for operation. IMM in Auto Active when IMM is cycling in Automatic.
  • Page 28 Other digital input to be used when necessary. 31 (21) This signal is optional. 0VDC of Controller A reference of pin 25 from the UltraSync-E for test functions. Also used for sourced digital outputs from the IMM, if necessary. Page 20...

  • Page 29: Safety Signals

    Figure 2-8). Its function is to operate as part of the IMM E-Stop circuit. The UltraSync-E E-STOP push button has two isolated, normally closed, signal channels that attach to the X100 connector pins 1/2 (channel 1) and pins 3/4 (channel 2). (Refer to...
  • Page 30 A check of the 0.6 second set time is done by the controller logic each time the safety relay is operated. The UltraSync-E screen shows an alarm if the time is not set correctly. The 0.6 second time check cannot be changed.

  • Page 31: Ethercat Connections

    EtherCAT In connector. EtherCAT Out is used to connect other Altanium devices. Figure 2-10 EtherCAT Connections 2.14 UltraSync-E Servo Motor Connection The connector location for the UltraSync-E servo motor cable is on the back and bottom of the controller cabinet (refer to Figure 2-1).

  • Page 32: Start The Ultrasync-E

    If applicable to your system, make sure that there is no blockage of the air filter cover on the rear of the UltraSync-E. Remove all materials around the air filter cover, so that there is good airflow into the air filter.

  • Page 33: Apply Power To The Ultrasync-E

    IMM E-stop is pushed and that an E-stop alarm occurs on the HMI. An E-stop alarm must occur on the HMI. 10. Make sure that the valve stems go to the closed position and the UltraSync-E stops when a guard or protective gate is opened.
  • Page 34 — March 2023 UltraSync-E Page 26...

  • Page 35: Chapter 3 Ultrasync-E Operation

    The screens shown in this user guide are from an Altanium Delta5 controller. The UltraSync-E screens on a Delta5 controller are the same as on a Matrix5 controller. The only difference is the display size. The operation of the UltraSync-E is the same for the two controller systems.

  • Page 36: Ultrasync-E Screen Tabs

    • Setup (Section 3.4) Labeled tabs at the bottom of the UltraSync-E screens give access to the Home, Profiles, and Setup configurations. UltraSync-E Configurations The UltraSync-E system can be installed and operated as a standalone with one or two axes or integrated with one or more of the products that follow: •...

  • Page 37: Dual Ultrasync-E System

    A Matrix5 controller can be configured to operate two UltraSync-E systems. This configuration is not available with a Delta5 controller. All functions are the same for each UltraSync-E, and they can be configured and operate independently of each other. With a second UltraSync-E installed, the differences on the controller are: •...

  • Page 38: Control Modes Buttons

    Figure 3-2 UltraSync-E Home Screen 1. Control Modes Buttons Drop-Down 2. Control Bar 3. Control Bar Status Fields 4. Manual Control Buttons 5. UltraSync-E Home Screen Tab 6. Opening Profile Tab 7. Closing Profile Tab 8. Setup Tab 3.3.1 Control Modes Buttons Use the Control Mode buttons to change the UltraSync-E mode between Disengaged and Engaged.

  • Page 39: Manual Control Buttons

    Calibrate This button starts the calibration sequence. 3.3.3 Ready Conditions The Ready Conditions status indicators show what steps are required to put the UltraSync-E into Engaged mode. The indicators are described in Table 3-3. Page 31...

  • Page 40: Control Bar Status Fields

    Indicates that the servo drive is powered and enabled. Calibration OK Indicates that the UltraSync-E is calibrated. 3.3.4 Control Bar Status Fields These fields give information about the status of the UltraSync-E servo system. The fields are described in Table 3-4. Table 3-4...

  • Page 41: Status Area

    Configure the UltraSync-E advanced options on the UltraSync-E Setup screen. The UltraSync- E can only be configured when the user level is sufficient and UltraSync-E is not engaged. On the Altanium Delta5 or Matrix5 Home screen, touch the UltraSync-E button and then touch the Setup tab.

  • Page 42: Monitoring

    — March 2023 UltraSync-E Figure 3-3 UltraSync-E Setup Screen 3.4.1 Monitoring The Monitoring section lets you set valve stem open and closed position and force tolerance ranges, as described in Table 3-6. Table 3-6 Monitoring Settings Monitoring Description Minimum...

  • Page 43: Other Settings

    UltraSync-E - Enable this check box to activate the UltraSync-E axis. Activate When the UltraSync-E is deactivated, it does not operate in Disengaged or Engaged mode, and any faults or alarms from UltraSync-E are ignored. At Temperature Valve stems cannot be actuated until the soak time countdown has Soak Time completed.

  • Page 44: Motor Thermal Status

    When this value gets to 100%, the motor is disabled to prevent damage. 3.4.4 Setup Buttons There are four Setup buttons on the UltraSync-E Setup screen. These buttons give access to the UltraSync-E configuration settings windows that follow: • Signals •...

  • Page 45: Input Signals

    — March 2023 UltraSync-E • Permit Disengaging • Engaged Mode Commands From the UltraSync-E Setup screen, touch the Signals button to see the Signals window. Refer to Figure 3-4. Figure 3-4 Signals Window 3.4.4.1.1 Input Signals Input signals to the UltraSync-E are configurable. The signal types used are: •...

  • Page 46: Permit Calibration

    Signal is “At Temperature”. This uses the heats at-temperature signal. Valve Stems Open This input is used to start the Stems Open command when UltraSync-E is in Command Auto/Engaged mode. The default Signal Type is “Digital Input” and the Signal is “UltraSync-E Stems Open Command”.

  • Page 47: Output Signals

    — March 2023 UltraSync-E 3.4.4.1.4 Output Signals The Output Signals area of the screen gives indicators for the UltraSync-E outputs that follow: • Ready And Engaged (Indicates that the UltraSync-E is in Engaged mode with no faults.) • Valve Stems At Open •...

  • Page 48: Maintenance

    From the UltraSync-E Setup screen, touch the Hot Runner button to see the Hot Runner window. Refer to Figure 3-6. Use the Hot Runner window to configure the UltraSync-E controller for the hot runner tool it is actuating. These settings can only be changed in Disabled mode. Page 40...

  • Page 49: Hot Runner Configuration

    Touch the Number of Valve Stem field and select the number of stems from the list. Hot Runner Generation Gen 1 refers to the first generation UltraSync-E design. Gen 1uses different settings than the current Gen 2 design. For the Gen 1 design: •...

  • Page 50: Motor Mounting

    3.4.4.3.2 Motor Selection There are three types of motors used for the UltraSync-E systems. The motor installed on your UltraSync-E system must be identified, so the controller software can operate the movements correctly. In the Motor Selection area of the window, touch the circle next to the motor installed on your system, so the dot shows for that selection.

  • Page 51: Pullback

    Writing, Measure, Verify, and Valid. The download process is complete when the Valid indicator illuminates. 3.4.4.4 Pullback Pullback is an optional motion that occurs after the stems Close motion. In the UltraSync-E Setup screen, touch the Pullback button to see the Pullback dialog window. Refer to Figure 3-7.

  • Page 52: Ultrasync-E Opening Profile And Closing Profile Screens

    The deceleration used for the open operation of the pullback motion. UltraSync-E Opening Profile and Closing Profile Screens Use the UltraSync-E Opening and Closing Profile screens to setup and view the motion profiles used to open and close the valve stems. The Opening and Closing Profile screens are...

  • Page 53: Chart View And Adjustment Selections

    — March 2023 UltraSync-E Figure 3-9 UltraSync-E Closing Profile Screen 3.5.1 Chart View and Adjustment Selections Table 3-12 shows a list of the chart view and adjustment selections used on the Opening and Closing Profile screens. Table 3-12 Chart View and Adjustment Selections...
  • Page 54 — March 2023 UltraSync-E Table 3-12 Chart View and Adjustment Selections (Continued) Button Description Used to set the scale for the chart traces that follow: • Position (when Position is selected for the chart X axis) • Time (when Time is selected for the chart X axis) •...

  • Page 55: Opening/Closing Profile Screen Settings And Indicators

    — March 2023 UltraSync-E 3.5.2 Opening/Closing Profile Screen Settings and Indicators Table 3-13 gives the descriptions of the settings that are common to both the Opening and Closing Profile screens. Table 3-13 Settings for the Opening and Closing Profile Screens...

  • Page 56: Opening Profile Graph

    — March 2023 UltraSync-E Table 3-13 Settings for the Opening and Closing Profile Screens (Continued) Opening and Description Minimum Maximum Default Closing Profiles Deceleration The deceleration limit of the step. 1 mm/s^2 500 mm/s^2 500 mm/s^2 May not be achieved, depending on travel distance of the step.

  • Page 57: Closing Profile Graph

    I/O Screens Use the I/O screens to see the status and setup the digital inputs, digital outputs, configurable signals, and safety signals that are transmitted between the UltraSync-E controller and IMM. The configurations found on the Digital Input and/or Output screens are organized under...

  • Page 58: Inputs

    Level Indicates the electrical state of the input or output at the pin on the connector on the outside of the UltraSync-E controller. This equals the logical state after the input or output has been inverted by a Normally Close signal.
  • Page 59 This signal is necessary for operation when not integrated with a heat controller. UltraSync-E Stems Open Command to open valve gates when controller is in Command engaged/auto mode. This signal is necessary for operation.

  • Page 60: Outputs

    Table 3-18 Inputs from the IMM (Continued) Signal Name Description Pin (s) UltraSync-E Stems Close Command to close valve gates when controller is in Command engaged/auto mode. This signal is necessary for operation if a Two Trigger system is used.

  • Page 61: Configurable Signals

    UltraSync-E Ready and Active when controller is enabled with no faults, in Engaged auto/engaged mode. UltraSync-E Stems at Open Active when all of the following conditions are true: -Valve gate controller is ready and engaged -Valve stems are at open position...
  • Page 62 — March 2023 UltraSync-E Figure 3-12 Configurable Signals Screen The Altanium Matrix5 controller has 18 configurable signals and the Altanium Delta5 has 6 (shown in Figure 3-12). The tabs near the bottom of the screen give access to the signals.

  • Page 63: Safety Signals

    Safety signals are non-configurable fixed signals hardwired to the safety relay inside the UltraSync-E controller. These signals are connected to the IMM safety gate and E-stop circuits to make sure the system is safe for the user. The system will not run unless these signals are correctly connected.

  • Page 64: Trend And History Plots

    • Opening Duration • Opening Peak Force For information about the use of the trend/history plots and setting the cycle mode configuration for the UltraSync-E, refer to Chapter 12 Data Recording in the Matrix5 or Delta5 user guide. Page 56...

  • Page 65: Calibrating The Ultrasync-E

    — March 2023 UltraSync-E Calibrating the UltraSync-E Each time Altanium is powered on it is necessary to calibrate the UltraSync-E in order to move the valve stems. To calibrate the UltraSync-E, do the steps that follow: Make sure that the UltraSync-E is in Disengaged mode. If not, do the sub-steps that follow: a.

  • Page 66: Drive Fault (Error Code #)

    — March 2023 UltraSync-E 3.9.1 Drive Fault (Error Code #) This fault from the servo drive system can occur for many reasons. To diagnose the problem, complete the steps that follow in order. NOTE: Refer to the Altanium Matrix5 or Delta5 user guide for information about alarms.
  • Page 67 — March 2023 UltraSync-E Figure 3-15 BMAXX 5000 Servo Drive Unit Table 3-22 identifies the BMAXX 4000 drive faults and gives their possible solutions. Table 3-22 BMAXX 4000 Drive Faults Fault Fault Solution Number Watchdog error Internal error. De-energize and then energize the power to the drive.
  • Page 68 Invalid warning code Internal error. De-energize and then energize the power to the drive. False FPGA version Contact Husky Service. Error in module A De-energize and then energize the power to the drive, do a check of the wiring to module, or replace module (if necessary).
  • Page 69 — March 2023 UltraSync-E Table 3-22 BMAXX 4000 Drive Faults (Continued) Fault Fault Solution Number Reduce the DC link voltage Plastic pressure has pushed on the stems before they reached the open position. Make sure that the injection does not occur until the stems are in the open position (do not inject while stems are opening).
  • Page 70 — March 2023 UltraSync-E Table 3-22 BMAXX 4000 Drive Faults (Continued) Fault Fault Solution Number Temperature sensor motor not Do a check to make sure that the black encoder connected Tm >=+300 °C (572 °F) cable is connected between motor and drive and not damaged.
  • Page 71 Navigate to the UltraSync-E Setup screen and look at the temperature sensor type assigned to the motor in the Temperature Sensor panel on the Hot Runner window.
  • Page 72 One Wire EEprom De-energize and then energize the controller 1937 Actual data were not picked up on and if the problem continues contact Husky. time 1938 No data is available yet Configuration Faults Alarm Description: Drive Fault: Configuration (Error Code XXXX)
  • Page 73 — March 2023 UltraSync-E Table 3-23 BMAXX 5000 Drive Faults (Continued) Feedback Faults Alarm Description: Drive Fault: Feedback Sensor (Error Code XXXX) Error Code Fault Solution Amplitude of the encoder signal too Do a check to make sure encoder cable is not small damaged and is connected to the motor.
  • Page 74 2009 Under voltage in DC link specifications. De-energize and then energize the controller and if problem continues contact Husky. Power Unit Over Temperature Faults Alarm Description: Drive Fault: Drive Over Temperature (Error Code XXXX) Error Code Fault Solution...
  • Page 75 Error Code Fault Solution 1007 Power unit safety relay De-energize and then energize the controller and if problem continues contact Husky. Motor Over Temperature Faults Alarm Description: Drive Fault: Motor Over Temperature (Error Code XXXX) Error Code Fault Solution Motor excess temperature Do a check of the area around the motor for a source of high heat.
  • Page 76 — March 2023 UltraSync-E Table 3-23 BMAXX 5000 Drive Faults (Continued) Motor I²t Overload Faults Alarm Description: Drive Fault: Motor Overload (Error Code XXXX) Error Code Fault Solution Motor I²t overload Do a check to see if too much force is being applied when motor is at position.
  • Page 77 2415 Timeout of transmit process De-energize and then energize the controller 2416 Timeout of receive process and if problem persists contact Husky. Feedback Warnings Alarm Description: Drive Warning: (Error Code XXXX) Error Code Fault Solution Warning Collision of frequency Do a check to make sure the encoder cable is not damaged and is connected to the motor.

  • Page 78: Alarm: Position Deviation Limit Exceeded

    Make sure that all safety devices operate correctly. Examine all the cables. Clean the UltraSync-E controller cabinet and touch screen of the display module. Examine the air filter area on the rear of the UltraSync-E controller. Each Month Examine all electrical components. Page 70...
  • Page 79 Make sure that there is no blockage of the air filter cover or the air outlets. If there is not sufficient airflow then damage can occur to the UltraSync-E. Examine the air filter (do this task more frequently if you operate the UltraSync-E where the airflow has a large quantity of contamination).
  • Page 80 — March 2023 UltraSync-E If applicable to your system, examine the air filter. a. On the rear of the UltraSync-E cabinet, remove the screws that attach the air filter cover. b. Remove the air filter cover. c. Remove the air filter from the UltraSync-E cabinet.

  • Page 81: Schematics

    — March 2023 UltraSync-E Chapter 4 Schematics The schematics that follow show the connections from the controller to the IMM. Page 73...
  • Page 82 — March 2023 UltraSync-E Page 74...
  • Page 83 — March 2023 UltraSync-E Page 75...
  • Page 84 — March 2023 UltraSync-E X100 Cable with Flying Leads from the Controller to the IMM Page 76...