Advanced Controls for Advanced Control

G2 Control System

Available on RS1 and S290
Proprietary software running on an Industrial PC
Interface to PC is via a touchscreen HMI
Upgrades for G1 equipment not available

Go to G2

G3 Control System

Available on D-750+ and D-1500+
Single PCB (“Winding Module) controls most functions
Replaces multiple circuit boards with single component
Field-installable upgrades for single-spindle G1 equipment

Next Generation Controls

Replacing nearly all of the circuitry in the legacy “G1” REELEX machines, G2 and G3 control systems offer reliability, advanced features and connectivity befitting the 21st century.

Control System Comparison

Control System Version	G1	G2	G3 / G4
Years Produced:	1975-2013	2013-2016	2016+
Machines:	All single and dual-spindle machines through 2012.	D-750s built from 2013 to 2016.D-1500s built from 2014 to 2018. All D-2000 and D-2050s, S290s and RS1s.	D-750s built after 2016. D-1500s built after 2018.
Operator Interface:	Thumbwheels, Keypads	HMI Touchscreen	HMI Touchscreen
Processing (CPU):	7803A Board	PC-Based CPU	Winding Module PCB
Encoder Handling:	W600 Board	W602 and W603 Board
Interface to CPU:	W401 Board
Interface from Controls:	W90 Board/W801 Board	A0B6-P Board
Interface with I/O:	7507 Board	I/O-48	PB-16

Software Features

Both G2 and G3 controls feature similar software incorporating advanced features that greatly expand the usability and functionality of the REELEX machine.

The Latest Coiling Software

Increased control over coil formation. G2 and G3 controls are loaded with the latest REELEX coiling software. Increase precision over coil density, and incorporate the revised hole taper programming to make payout holes straight, while eliminating “lumps” in the coil.

Advanced Tension Control. When paired with a digital regulator, the software allows each product can have their ideal tension control map, helping to mitigate the effects of physical pressure placed on the cable at the crossover point.

On-Screen REELEX Calculator. The calculator allows process engineers to select different machine settings for different products and see the impact on coil and package sizes. When finished, a single button sets up the machine to wind the calculated product.

Product Storage and Machine Setup

Product Recipe Storage and Callup. Product settings can be saved with a ID or part number as well as a detailed description. Switching products is as simple as pressing which part number is being packaged.

Extensive Equipment Setup Options. Spark testing, sequential printing, footage scaling, online and offline operation are all supported and configurable via HMI.

Control over Machine Behavior. Easily change how the machine behaves when it encounters a print signal, spark fault and more. Easily set up the machine for online, offline, sequential printing or alternate modes of operation.

Machine Security

Security Username and Passwords. Users can be defined and prevented from changing certain settings or accessing certain parameters.

Restrict Specific Screens. Configure access for maintenance, settings and product select screens separately.

Operator Login. Turn on the operator login screen to record who is using the machine and when.

Safety, Maintenance and Troubleshooting

Safety First. With G2 and G3 controls, the status of nearly all machine functions are displayed on screen – no need to stop or get into the machine in order to understand valve or switch status.

Maintenance Readouts. Maintenance screens display valve, switch, encoder and sensor function in real-time to help in diagnosing issues and without opening up control cabinets.

On-screen Manuals. A comprehensive manual is available via the help screens, including procedures, preventative maintenance schedules and more.

Networking and Analytics

Ethernet Networking. G2 and G3 allow REELEX machines to send and receive data to a central location or interface with other equipment in the line. Running a product can be as easy as scanning a barcode on a work order. Communicating with other devices is simple and customizable, and web access is supported if required.

Built-In Analytics. See number of coils produced in an hour or an 8-hour shift, see the lengths of the last 100 coils produced or download the machine logs via USB or network.

Raw Data Output. Access the raw modbus data for use in IoT industrial monitoring services such as Wonderware®

Designed Around Humans

Multi-Language Support. The HMI can be configured to display in multiple languages including spanish, portugese, korean, chinese, japanese, turkish, polish and more.

Intuitive User Experience. The HMI is divided into Home, Products, Settings and Maintenance screens, each with content-specific help files. Navigating the HMI is simple and intuitive, with information right at your fingertips.

Comprehensive On-Screen Help. Screen-specific help screens tell you what you need to know based on what you’re doing. Detailed troubleshooting manuals are on-screen as well including best practices, problem solving and more.

HMI Interface

Interfacing with both G2 and G3 controls is a high-definition Red Lion Graphite 12-inch HMI running proprietary REELEX software. This software brings REELEX equipment deep into the 21st century, with real-time troubleshooting, multi-language support, recipe functions, networking functionality and more.

HMI Screens

Home Screen

The Home Screen is a read-only screen and is the operator’s primary readout screen while the machine is running.

Information includes product name, footage counter (in meters or feet), preset stop lengths, spark, lump and printing notifications, messages, production run length and more.

Product Selection

Once saved on the settings screen, the product select screen displays up to 200 products by part number or unique ID.

Changing machine settings is as simple as pressing the product being run. A wide range of settings such as coil parameters, tension, footage and more are saved to each product for one-press retrieval.

Settings Screen

The Settings screen allows the user to change coil parameters, speed settings and much more and save these settings to a Product ID. The product can later be called up on the Products screen, and all applicable settings are downloaded into the machine.

The user can also access the Packaging Calculator from here and have the computer suggest product settings to achieve a desired coil size.

Machine Setup

Machine setup and configuration is intuitive and is achieved on the Setup screen. Here, the user can change the machine operation modes, alter machine behavior when a spark or fault is encountered, and set up online printing parameters.

Maintenance

Maintenance screens provide real-time readouts of what’s going on inside the REELEX machine.

Valves, switches, I/O, encoder and sensor positions are all viewable in real time without having to open the control cabinet.

On-Screen Help

A comprehensive help manual is available on screen. From packaging to maintenance to setup, all information pertaining to the individual machine is available at the touch of a finger.

Screen-specific help screens display help information relevant to the last screen displayed.