G2
PC-Based REELEX Control System

The Standard in REELEX Controls.

Originally debuting on the D-2000, the G2 control system now powers most REELEX equipment and has been the standard controls for most REELEX machines since 2012. Starting in 2018, the G3 control system will replace G2 on some equipment.

G2 Overview

The G2 Control System is a completely new operating system, hardware, cabinet and interface for all REELEX coiling machines. Integrating equipment control with troubleshooting, on-screen manual, packaging calculator, multi-language support, product storage, networking capability and more, the G2 Control system is designed for 21st century industrial environments.

At the heart of the G2 control system is an industrial-pc handling software calculations interfaced by High-Definition 12-inch wide-screen touchscreen HMI programmed in-house.

The G2 Control System is currently standard on RS1, S290, D-1500 and D-2050 REELEX machines.

Industrial-PC Based

Modern hardware means modern performance. Behind the G2 Control System is an industrial PC running a proprietary and highly reliable operating system. PC components are off-the-shelf and can be replaced easily and affordably.

70% Reduction in Unique Circuitboards. The PC in the G2 Control System replaces several functions that were previously handled by sometimes finicky and unique circuitboards. This greatly improves reliability and servicability.

Digital Controls

Digital Inputs. Improving reliability, easing troubleshooting and hugely improving accuracy and ease of tuning.

No thumbwheels or keypads. G1 D-750 and D-1500 users will be pleased to know there are no thumbwheels or keypads – all inputs are now handled by the HMI.

Proprietary HMI Software. Unique to REELEX equipment, the custom HMI software provides intuitive setup and control over the machine.

Easy Maintenance and Tuning

Ergonomic Maintenance. For maintenance staff, working on G2 REELEX machines is simple and intuitive. Cabinets are clean, organized and a computer terminal makes running a (greatly improved) troubleshooting program a snap.

24 Volt Operation. Increased safety and serviceability.

Cleaner, consolidated components. Opto racks have consolidated into one, power supplies are simpler and easier to service, wiring is clear and easy to troubleshoot.

On-Screen Maintenance. Many issues can be diagnosed without ever having to open the cabinet. Other issues can be resolved using the built-in troubleshooting program.

Digital Air Regulation

Upgrade your dancer. Machines upgrading to G2 controls will also have their dancer equipped with a digital air regulator. This allows HMI control over tension. Applies only to REELEX-built dancers. Dancers not manufactured by REELEX will require an engineering review and part costs may be charged to the customer.

G2/G3 Software Features

The Latest Coiling Software

Increased control over coil formation. G2 and G3 controls are loaded with the latest REELEX coiling software. Take advantage of increased 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. This feature has shown to improve electrical properties of twisted-pair cables.

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.