Product Manual
Contents
1. L CND J10 Jil dle J13 D I EGEN JE JE TE 0 0 610100010 01010190 Ip JE J9 s IE D MERI HIL fi 2 3 4 5 Hep AM ae 2 ov WH CO HCH IOC O lO Ol O lO GIOIO O GND POST WHT eli 2 BR BLK YEL GND GR GND PIN BLK GREY GR WHT AC INPUT CORD wm CABLE LL COMMUNICATION SHIELD e N OFF INJECTION cam SCREW RECUVE _ E S MOTOR T EXTRUDER FULLUWER PIWER gt n D vu BRN YEUGen PINK GRE CABLE DI UG 4 4 J la Velt D9 PLUG 4 pols Series C16 1 s SE ST 4 we LE u y BLUE ni lt Ll p m 3 A SENSUR optional Hl es p iv d S 2131415 ADDITIVE BATCH EE AL AP SE F lt gt J SVDC COM TOL 3 7 i R 7 Y S S DI 0 Li Ogi a p n BLACK e R UE T BROWN 2 KEL M n 5 BLACK cl 74 Dosing Unit Electrical Schematic Chart for Bauer blue motors only C150 CONTROLLER EXT C EXTRUSTION 0 20 mA INPUT CT102024 C150 CONTROLLER INJECTION CT102025 C150 CONTROLLER EXT S EXTRUSION SIMPLE EXTRUSION CT1020262. 185MM CONTROLS E 45 VDC CONTINUDUS STEP 0 VIC RUN 15 VDC MOMENTARY ACKNOMLEDGES ALARMS WHT KN BRN Y SHIELD VE SWITCH COLORBLEN DER UND STANDAR FEE IRB CAUTION SHOCK x VARNINGER MOTOR WAS FULL VOLTAGE WHILE STOPPED BLACK Ge SINGLE PHASE POVER IN IRBS DN UITIUIIL rm art COM LIL GREENYYELLOW BLACK J 3 gt lt 73
3. 18 Mount the profile clamp 19 Mount the screw at the profile clamp and tighten 5 7 Exchangeable Stations Dosing discs of the same type may be exchanged for each other without any problems If dosing discs with a different compartment number are installed this has to be entered in the control system 1 Enter the preliminary calibration value of the freshly installed dosing disc DT Discs Calibration Number of Number Pockets DT 30 101820 32 00 20 DT 30 102025 38 00 25 DT 30 203012 100 00 DT 30 204010 175 00 DP Discs Calibration Number Disc Number of Thickness Pockets 2 Execute calibration to determine the final calibration value Digital Dosing Units 52 5 8 Replacing Fuses 1 Stop the continuous operation 2 Wait until the dosing unit has stopped 3 Switch off the device with the on off switch 4 Cut off the voltage supply 5 Wait at least one minute before starting to work at the unit or controller 6 Never try to repair a defective fuse 7 Open the screws A and remove the lid B 8 Remove the blind lid C and open the SCrews 9 Move the lid D aside 10 Remove the defective fuse from the fuse carrier 11 Install the new fuse while observing the value 12 Mount the lid D 13 Fasten the screws and the blind lids C 14 Mount the lid B 15 Mount the screws A See Appendix D for fuse part numbers Digital Dosing Units 53 Appendix
4. Diameter Disc Thickness Default Calibration 7 8 grams rev 0 2 Rev min 6 4 RPM 0 5 Rev min 11 5 RPM 1 0 Rev min 35 5 RPM 0 2 Rev min 6 4 RPM 0 5 Rev min 11 5 RPM 1 0 Rev min 35 5 RPM 0 2 Rev min 6 4 RPM 0 5 Rev min 11 5 RPM 1 0 Rev min 35 5 RPM 151 15 g Rev 15 12 g Hole 15 64 g Rev 0 39 g Hole 7 82 g Rev 0 20 g Hole 4 00 Ib hr 1 80 kg hr 10 00 Ib hr 4 53 kg hr 20 00 Ib hr 9 00 kg hr 0 41 Ib hr 0 187 kg hr 1 00 Ib hr 0 45 kg hr 2 00 Ib hr 0 94 kg hr 0 20 Ib hr 0 093 kg hr 0 46 Ib hr 0 21 kg hr 1 00 Ib hr 0 47 kg hr 128 00 Ibs hr 59 00 kgs hr 227 74 Ibs hr 103 28 kgs hr 705 00 Ibs hr 320 00kgs hr 13 20 Ibs hr 6 00 kgs hr 22 62 Ibs hr 10 62 kgs hr 73 40 Ibs hr 33 30 kgs hr 13 2 Ibs hr 3 00 kgs hr 10 55 Ibs hr 4 78 kgs hr 36 70 Ibs hr 16 65 kgs hr 188 72 g rev 18 87 hole 19 53 g rev 0 49 g hole 9 76 g rev 0 245 g hole 5 0 Ibs hr 2 25 kg h 12 43 Ibs hr 5 64 kgs hr 25 00 Ibs hr 11 30 kgs hr 0 51 Ib hr 0 23 kg h 0 12 Ib hr 0 57 kg hr 2 60 Ibs hr 1 17 kgs hr 0 26b hr 0 115 kg h 0 60 Ib hr 0 27 kg hr 1 30 Ibs hr 0 58 kg hr 160 Ibs hr 72 5 kgs h 283 Ibs hr 129 kgs hr 886 Ibs hr 402 kgs hr 16 50 Ibs hr 7 50 kgs h 28 65 Ibs hr 13 80 kgs hr 91 70 Ibs hr 41 60 kgs hr 8 25 Ibs hr 3 75 kgs h 13 57 Ibs hr 6 15 kgs hr 45 85 Ibs hr 20 80 kgs hr
5. Sterling SDD Series Digital Dosing Additive Feeders Part Number 882 00276 00 Bulletin Number BF3 600 2 Effective 11 01 06 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2006 All rights reserved Table of Contents SECTION T INTRODUCTION WE CI Ga KOR COEN Be n DOS E 6 SECTION 25 QUICK START UP 8 BASIC INPUT PARAMETERS INJECTION MOLDING 12 BASIC INPUT PARAMETERS EXTBUS ON 16 SECTION 3 INITIAL INSTALLATION AND OPERATION eennnnnnnnnnnnnnnnnnnnnnnnnnnennnn0 20 S INTENS EASTON sanoi 20 3 2 IME kele cl ea gd GN 23 29 d Vue nelle ne tesiei 24 3 4 Extrusion Constant 29 3 5 Extrusion Proportional Extruder tracking or follower 34 DO AIM AU Ol DEE 38 SECTION 4 ADVANCED OPERATIONS CONTROL FUNCTIONS E 41 4 1 Recipe Storage ReCalll KA 41 4 2 Clearing the e 43 23 ACOMEdaNg E EE 43 AA ENN 44 SECTION 5 MAINTENANGE E demand O eh RU Eelere 46 5 2 Removing the Shear Plate DD feeder only EEEU UUE 46 5 3 Cleaning the DD Dosing Giaton 47 5 4 Changing the Dosing Disc in the DT Dosing Station 49 5 5 Removing Replacing the Wiper in
6. also be activated e Alarms are acknowledged by pressing AA e The alarm will also initiate an error code e See Appendix A for Troubleshooting suggestions for various alarms e The alarm condition must be corrected prior to beginning operation again Digital Dosing Units 43 4 4 Optional Equipment Level Switches and Communications Options Optional equipment for the Digital Dosing Additive Feeder includes Alarms Several alarm options are available for the Digital Dosing feeder The standard unit comes with a flashing alarm symbol 0 7 on the faceplate Options include both audible horns and flashing lights An optional no voltage alarm relay can be connected to the user s central alarm system Level switches probes To adjust the level switches 1 Turn the controller ON 2 Fill the dosing station until the level sensor is one third covered 3 Remove the small plastic screw M3 on the back of the level sensor see Figure 7 LED Yellow Station LED Green Level Probe on Station Filled on Power Supply Available off Station Emptied off Power Supply Not Available npn Normally Closed npn Normally Open pnp Normally Open 0 pnp Normally Closed Blind Lid Trim pot with Protective Screw Plastic Screw M3 Gab Level Probe Figure 7 Level Sensor Screw 4 Turn the trim pot until the yellow control lamp just switches off Digital Dosing Units 44 NOTE Turning the trim pot to the left decreases the
7. C150 CONTROLLER EXT V EXTRUSION 0 10 V INPUT CT102027 C150 CONTROLLER EXT C EXTRUSION 0 20 mA INPUT Note 1 If changes to the controller are required please consult factory 2 Request any additional drawings needed at that time Dosing Unit Electrical Schematic Chart for Bison black motors only Drawing No Description of Drawing Voltage CT101675 C150 CONTROLLER EXT S SIMPLE EXTRUSION CT101676 C150 CONTROLLER EXT V EXTRUSION 0 10 V INPUT 110 CT101677 C150 CONTROLLER EXT C EXTRUSTION 0 20 mA INPUT 110 110 CT101753 C150 CONTROLLER INJECTION 220 CT101750 C150 CONTROLLER EXT S EXTRUSION SIMPLE EXTRUSION 220 CT101751 C150 CONTROLLER EXT V EXTRUSION 0 10 V INPUT CT101752 C150 CONTROLLER EXT C EXTRUSION 0 20 mA INPUT Note 1 If changes to the controller are required please consult factory 2 Request any additional drawings needed at that time 75 Appendix D Spare Parts List Dosing Disc Shear Order Numbers 18 25 40 pocket disc Replacement Motor Order Numbers Bauer Gear Motors 6 4 RPM CT34300 11 5 RPM CT102241 35 5 RPM CT34299 76 Control System Order Numbers Voltage Part Number 5X20 250 V A0571836 1 4X1 1 4 250 V Time Delay CT99107 zm HA ode ol a oda JE JE Jit Jii Ji2 2913 a J Z TI Notes 78 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 783 7835 The ACS Customer Service Group will provide your company with
8. gt Default Calibration 13 5 grams rev DT30 101820 AT K ASE VIN OO A Z oD Do ARK VEN ng d E an w ee Fo ad j NA j gt ace EE EEE EEE ERE CO ef Se LAY gt Wa KN 7 za em N VAN A pak WAAdFKT gt SIT j E ep Default Calibration 28 grams rev DT30 102025 Sure Shot disc No Picture Default Calibration 33 grams rev DT30 203012 S SE fics Pel Z N l Sase DN Laf JAN lt S st L FE PA f JPP MY ML ee Default Calibration 95 grams rev QE NP 051818 of Holes Diameter Disc Thickness 101820 of Holes Diameter Disc Thickness P102025 of Holes Diameter Disc Thickness 203012 of Holes Diameter Disc Thickness 0 2 Rev min 0 35 Ib hr 11 40 Ibs hr 6 4 RPM 13 42 g Rev 17 08 g rev 0 75 g Hole 0 16 kg hr 5 15 kgs hr 0 95 g hole 0 5 Rev min 11 5 RPM 0 85 Ib hr 19 60 Ibs hr 1 0 Rev min 35 5 RPM 0 39 kg hr 8 89 kgs hr 1 76 Ib hr 63 00 Ibs hr 28 60 kgs hr 0 2 Rev min 0 75 Ib hr 23 70 Ibs hr 6 4 RPM 28 00 g Rev 35 63 g rev 1 40 g Hole 0 34 kg hr 10 75 kgs hr 1 78 g hole 0 5 Rev min 11 5 RPM 1 85 lb hr 42 23 Ibs hr 1 0 Rev min 35 5 RPM 0 84 kg hr 19 15 kgs hr 3 7 Ib hr 131 50 Ibs hr 1 68 kg hr 0 87 Ib hr 59 70 kg shr 27 94 Ib hr 0 2 Rev min 6 4 RPM 33 60 g Rev 42 75 g rev
9. 1 3 g Hole 0 40 kg hr 12 67 kg hr 1 71 g hole 0 5 Rev min 11 5 RPM 2 18 Ib hr 49 77 b hr 1 0 Rev min 22 57 kg hr 35 5 RPM 0 99 kg hr 4 36 lb hr 154 90 Ib hr 1 98 kg hr 2 51 Ib hr 10 29 kg hr 80 50 Ibs hr 0 2 Rev min 6 4 RPM 95 09 g Rev 118 72 g rev 7 92 g Hole 1 14 kg hr 36 50 kgs hr 9 89 hole 0 5 Rev min 11 5 RPM 6 28 Ib hr 143 28 Ibs hr 1 0 Rev min 35 5 RPM 2 85 kg hr 65 00 kgs hr 12 50 Ib hr 446 54 Ibs hr 5 70 kg hr 202 50 kgs hr 64 0 44 Ib hr 0 20 kg h 1 12 Ibs hr 0 51 kg hr 2 20 Ibs hr 1 00 kgs hr 1 00 Ibs hr 0 43 kg h 2 31 Ibs hr 1 05 kgs hr 4 70 Ibs hr 2 14 kgs hr 1 12 Ibs hr 0 50 kg h 2 77 Ibs hr 1 26 kgs hr 5 55 Ibs hr 2 52 kgs hr 3 13 Ibs hr 1 42 kgs h 7 80 Ibs hr 3 54 kgs hr 15 65 Ibs hr 7 1 kg shr 14 5 Ibs hr 6 56 kgs h 25 63 Ibs hr 11 62 kgs hr 80 25 Ibs hr 36 4 kgs hr 30 1 Ibs hr 13 68 kgs h 52 78 Ibs hr 23 94 kgs hr 167 3 Ibs hr 75 9 kg shr 35 56 Ibs hr 16 12 kgs h 63 34 Ibs hr 28 72 kgs hr 197 25 Ibs hr 89 46 kgs hr 100 53 Ibs hr 45 6 kgs h 178 Ibs hr 80 kgs hr 557 Ibs hr 252 9 kgs hr 204010 DT30 204010F of Holes Diameter Disc Thickness Default Calibration 150 grams rev DP30 050940 P050940 ATT VU D of Holes Diameter Disc Thickness Default Calibration 15 grams rev P250940 of Holes
10. A Troubleshooting During setup and use of the Digital Dosing Additive Feeder personnel may experience difficulties Some of the problems encountered may be resolved using the following techniques A 1 General Troubleshooting Unit Will Not Operate e Check all connections and process wiring Note that the process machine input MUST be wired to a DRY contact for Injection Molding Section 3 1 and Extruder Constant Applications Section 3 1 For Extrusion Proportional Applications Extruder Follower OPTION see Section 3 5 e Ensure the correct Configuration Codes have been entered to configure the Digital Dosing unit for the process and installation see Section 2 A 2 Malfunctions Error Codes When a malfunction or error occurs the controller displays the Alarm symbol 17 and an error code The code consists of an A followed by an error number The control unit will not operate until the malfunction or error has been corrected To acknowledge and clear the alarm press the Stop key Ve Once the malfunction is corrected press L Io begin dosing operations SH will not correct a malfunction or error NOTE Stop Following is a table with the error codes possible reasons for each code and solutions to the problems presented Digital Dosing Units 54 ERROR CODES Code Possible Reason Solution A001 Strap safety switch is missing Manufacturer Service A002 The nominal current
11. Press and hold the button until the totalizer display returns to the screen e The recipe is now stored under the selected ID number Recipe Recall Step 1 Press ke LED displa displa OT Pre totalizer op e Press the stop button to stop any current applications Step 2 Press ke LED displa displa L load Y and the mostrecently called up recipe number Eg e Press the Storage Recall key once e A two digit recipe ID number will appear on screen Step 3 e Use the Arrow Keys Vv h A A to select the desired recipe number Digital Dosing Units 42 Step 4 Press ke LED displa displa i call up recipe gt 25 Ba baw F m gt e Press and hold lt gt until the totalizer appears on the screen e The recipe is now active and can be run or edited NOTE The recalled recipe now becomes the active recipe 4 2 Clearing the Totalizer e The totalizer displays the total amount of additive dosed since the last time the totalizer was cleared e The totalizer can be cleared by pressing Stop Y continuously for 5 seconds until the display is reset to 00 00 The totalizer can be configured to read throughput in grams or pounds e See Appendix A to learn how to change the unit of measure 4 3 Acknowledging Alarms e When an alarm occurs the Alarm symbol 17 flashes red and the dosing process stops e lf the Digital Dosing is equipped with an audible alarm or flashing light it will
12. Specification Sheet DIGITAL DOSING UNIT TECHNICAL PARAMETERS Disc Dosing Factor Table 2 Maximum Number of Feed Stations One 1 for Granule Processing 20 kg 44 pounds Special Voltage On Request Option Hopper Level Probe Additive Option Hopper Level Probe Virgin 66 Starter Calibration Parameters DD Discs Calibration Number DD 30 030673 1 2 Shot size of the current mold _Grams pounds Using the arrow keys set the shot size of the current capacity in grams min or pounds min 4 Calibration weight for additive Grams Enter a value from the tables below and proceed to calibration mode to set the calibration value 18 Totalizer display only Grams pounds Digital Dosing unit parameter setup 1 4 for extrusion contant Parameters Detaut Units 1 Additive Percent Using the arrow keys set additive ratio 2 throughput Grams pounds _ Using the arrow keys set to the throughput of the extruder capacity in grams min or pounds min 3 Not used 4 Calibration weight for additive Grams Enter a value from the tables below and proceed to calibration mode to set the calibration value Totalizer display only Grams pounds Digital Dosing unit parameter setup 1 4 for extrusion proportional Parameters Detaut Units Additive Percent Using the arrow keys set additive ratio S throughput RE Using the arrow keys set to the throughput of the extruder capacity in grams min or pounds min Extruder speed
13. The green LED will light when the unit is ready to dose Press key LED displa displa Por b ra Pa totalizer throughput AA ratational speed ofthe dasing mator nominal current of the moter in gt 22 gt gt Ale e Start the molding machine The Digital Dosing feeder will not dose material until the molding machine screw recovers If the unit is installed properly the process machine symbol We will light on the controller during screw recovery The disc symbol will light when the Digital Dosing unit is dosing material e The totalizer will increase after each cycle by the amount of material dosed Digital Dosing Units 28 e To stop the dosing process press AA e While the unit is dosing the current recipe can be viewed but not modified by pressing shots measured from the molding machine To change the recipe the unit must be taken off line by pressing the stop key The run LED will then go out NOTE See Appendix A Troubleshooting for information on problems or errors encountered and their resolution 3 4 Extrusion Constant Standard In Extrusion Constant operation the Digital Dosing unit doses material at a constant rate that does not change with extruder speed The dosing process begins at the startup of the extruder How close the actual extruder speed is to the input recipe will determine the accuracy of the blend If the process requires the additive to be dosed in proportion to
14. Using the arrow keys set the RPM 4 Calibration weight for additive Grams Enter a value from the tables below and proceed to calibration mode to set the calibration value Totalizer display only Grams pounds Set up of Factory Set Operating Parameters Digital Dosing unit parameter setup 7 14 Bison Black motor Bauer Blue motor Comments Parameter RPM 2 6 12 38 6 4 11 5 35 5 65000 25200 14103 4387 11739 6600 2135 These values refer to the pulses of the encoder 0 5 0 Nominal motor current 1040 1040 16 see separate calculation sheet for parameter 9 Factory set do not change ji 50 Ext minimum input frequency w follower only Inj Minimum of machine cycles per dosing al N Inj 68 10 5 56 10 5 56 Ext Span factor sf calculated using sf 1000 rom 10vdc sf 1000 rom 20ma Ext Inj i Communication address used with Euromap 17 use 1 instead of 0 220 220 220 ___ z20 For use with Micro mix hopper use 1 instead of 220 69 Station 1 Digital Dosing Unit E EL d A SS K Le L ab Ta Uu bk e KE P na mm e SIDE VIEW 159 men a f 1G ma FO ga i F k K TOP VIEW 71 Station 2 Digital Dosing Unit P F l SIDE VIEW i a LUT TOP VIEW General Wirinq Diaqram for Bauer Motor ec VAL JUMPER a 3 ERE A Aen JAER POSITION POSITION
15. affected by machine vibration therefore best performance is achieved by mounting the unit directly to the feed throat of the molding machine or extruder see Figure 4 The inlet into the process machine must be greater than 2 diameter otherwise an adapter might be necessary If an adapter is necessary it must be designed so that there are no edges where material can be trapped The adapter must be smooth to promote even material flow Consult factory for any special requirements 2 Optimum mounting of the Digital Dosing feeder is shown in Figure 4 with the additive being dosed on the first screw flights 3 The controller can be mounted on either side of the blender base to optimize operator interface An optional remote mounting kit for the controller is available from the manufacturer to relocate the controller closer to the operator The control unit must not be exposed to extreme heat maximum temperature 45 C or 115 F or excessive moisture Digital Dosing Units 20 4 Electrical connection to process machine NOTE NOTE NOTE e Injection Molding Connect the cycle run slave cable thin two conductor cable to a set of DRY NO VOLTAGE contacts that CLOSE for the duration of screw recovery See Figure 5 electrical diagram Relay contact Injection molding Digital Dosing controller Machine Electrical diagram of connections Figure 5 Electrical Diagram Extrusion Constant Wire the cycle run slave cable
16. calibration weight in grams or pounds afa N e Press E a third time e The machine displays a flashing g or lb and a number 4 flashes on the display e After the 4 flashes on the display a number in the format xxxx x will come up e Enter the calibration weight in grams If the calibration weight is unknown enter the appropriate value from Section 2 based on your disc size to obtain a starting weight e The range of values that can be entered in this field is 00 00 to 400 0 Note Parameters 5 and 6 will only be displayed when a mixer and or a printer is configured Digital Dosing Units 30 Step 4 Press ke LED displa displa EL T e B maintained running time of the blending ai unit in seconds e Press again and the symbol s will light up and the number 5 will be displayed if you have a blending unit and have invoked this option e After 5 flashes on the display a number in the format xxx xx will come up on the display e Enter the maintained running time of the blending unit in seconds using the arrow keys This is how long the blender will run after each dosing cycle and should be adjusted for the best possible blend Too little time may not produce good dispersion too much time can cause separation especially with heavy concentrates Step 5 Press ke LED displa displa he Ka printer mpu Only if a printer optional is available enter printe
17. genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 24 hours at 800 783 7835 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 262 641 8610 Monday Friday 8am 5pm EST Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm EST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Sterlin 2900 S 160 Street New Berlin WI 53151 262 641 8610 73
18. lt r x wana 8 aed dh wie snever sed ease 16348 _____ Example e Level probes additive probe installed e Shot weight 8 kg e Totalizer displayed in Ib Raw material probe aauava navna ee an 1 Digital Dosing Units 61 Additive probe Blending unit Totalizer displayed in Ib shot weight up fopnkg 2 2c eee Or SNOt Wwelght 6 5 10 09 KO0 NEE External run stop signal controls dosing 08 Mounting on a Micro mixing hopper Alarm output switched in case of power failure Printer available Digital Dosing Units 62 8 SC 16 16 0 32 3 64 256 ___ 51412 16348 50 Appendix C Dosina factors equipment drawinas and part numbers Disc Dosing Factor Table 1 Disc Guide Disc Minimum Nomenclature Maximum Used in the Disc Controller Revolution Revolution P030672 0 2 Rev min 6 4 RPM 1 53 g Rev DD30 030672 of Holes Diameter 0 5 Rev min Disc 11 5 RPM Thickness 0 02 g Hole 1 0 Rev min Default 35 5 RPM Calibration 1 50 grams rev 0 2 Rev min 6 4 RPM D30 051 040 051040 4 24 g Rev Diameter 0 5 Rev min Disc 11 5 RPM Thickness 0 11 g Hole 1 0 Rev min Default 35 5 RPM Calibration 4 0 grams rev 051725 0 2 Rev min 7 37 g Rev of Holes 6 4 RPM Diameter 0 30 g Hole Disc 0 5 Rev min Thickness 11 5 RPM WARM 1 0 Rev min Default 35 5 RPM Ca
19. plate Digital Dosing Units 50 8 9 Tighten down the 3 plastic screws Make sure that the wiper is fitted parallel to the dosing plate Use only plastic screws to avoid damage to the extruder or molding machine screw should the mounting screws ever come loose Install the dosing container along with the dosing hopper on the dosing housing pay attention to the guide pins 10 Mount the profile clamp 11 Mount the screw at the profile clamp 5 6 Cleaning the DT Dosing Station 1 2 10 11 12 13 14 15 Empty the dosing station Switch the control unit off by means of the on off switch Disconnect from mains voltage Open the profile clamp C of the dosing container Remove the profile clamp C Remove the dosing container B along with the dosing hopper A Open the safety screws at the toggle type fasteners Open the toggle type fasteners Togge lype fasiener Remove the dosing housing D from the mixing hopper Clean the dosing housing D with a paintbrush Clean the dosing container B and the dosing hopper A in soapy water Dry all parts thoroughly Mount the dosing housing onto the dosing motor Observe that the guide pins are locked into position Close the toggle type fasteners Digital Dosing Units 51 16 Mount the safety screws 17 Install the dosing container along with the dosing hopper on the dosing housing pay attention to the guide pins
20. screw recovery time in seconds This time represents the amount of time the molding machine screw is in recovery This value is an estimate The Digital Dosing unit measures the actual recovery time and automatically updates this value during operation NOTE The range of values that can be entered in this field is 2 00 to 99 99 seconds Digital Dosing Units 25 Step 4 Press ke LED displa displa 4 calibration weight in grams or pounds Pe um e Press Input a fourth time e The symbols g or Ib and flash e After 4 quickly flashes on the screen a number in the format xxxx x will come up on the display e Enter the calibration weight in grams If the calibration weight is unknown enter valve from section 5 7 knowing you Disc size to obtain a starting weight e The range of values that can be entered in this field is 00 0 to 400 0 Please note Parameters 5 and 6 will only be displayed when a mixer and or a printer is configured Step 5 Press ke LED displa displa R E maintained running time of the blending unit in seconds e Press 2 again and the symbol s will light up and the number 5 will be displayed if you have a blending unit and have invoked this option e After 5 flashes on the display a number in the format xxx xx will come up on the display e Enter the maintained running time of the blending unit in seconds using the arrow keys This is how long
21. the DT Dosing Station 50 5 6 Cleaning the DI Dosing Station l dayik anha a kena dihan A ean h k Ata BA an 49 ow Exchangeable Le EE 52 590 ER nie Ha Te BEE 53 APPENDIX A TROUBLESHOOTING uennnnnennnnevnnnennnnennnennnnnnnnnnnneunnenneennnnnennnn0 D AT EST EI Rei e e dn Le DEE 54 A 2 Malfunctions Error Codes ssie n Aa EOE 54 A 3 Determining the Software Setup Factor L4 56 A4 Recipe en siy ia i4 0l14 5olyno baniyan b ne latelan l a i kn l n n an a VARA AWA W a DANA VAAN 56 APPENDIX B BASIC PARAMETER SETTINGS rannrnnnvnnnvnnnnnnnvnnnnnnernnnvnnnnnnvnnnen 08 APPENDIX C DISC DOSING FACTORS DRAWINGS AND PARTS NUMBERS 63 APPENDIX D SPARE PARTS LIST kk TO APPENDIX E Technical ASSISt ANCE 00ccecceecenccncceeceeseusceusseucessssenessscesssssneeesl Q Digital Dosing Units 2 Section 1 Introduction This User s Manual is intended for use with the Digital Dosing Disc Additive Feeder The feeder precisely meters and controls the addition of master batches chemical additives and regrinds to primary plastics The Digital Dosing unit can meter both powder and granular material of various sizes lt can be used on extrusion blow molding and injection molding machines Depending on the application and throughput two models are available Single Station Digital Dosing Unit or Dual Station Digital Dosing Unit See Figures 1 and 2 This manual covers the operatio
22. the blender will run after each dosing cycle and should be adjusted for the best possible blend Too little time may not produce good dispersion too much time can cause separation especially with heavy concentrates Digital Dosing Units 26 Step 6 Press ke LED displa displa KN Ka printer gr Only if printer optional is available enter printer parameters no printing 1 printing setpoints 2 printing parameters 3 page change 4 printing each event D printing alarms e Pressing 2 again will activate the printing option if it is available e After the 6 flashes on the screen a number in the format xxx xx will come up on the display e By using the arrow keys you can choose your printer parameters Step 7 Press ke LED displa displa lt gt Pe total throughput in k input a gt 1 Pressing e again will first display the number 18 and then will display the total throughput in kilograms totalizer Digital Dosing Units 21 Operation Injection Molding 1 Ensure that the unit is properly installed Section 3 1 a recipe is entered section 3 3 1 and the feeder is calibrated Section 3 6 before attempting to begin operation 2 If desired clear the totalizer by holding the Stop key Ve continuously for five seconds until the display is reset to 00 00 3 Place the Digital Dosing feeder into operation by pressing the Run key Va
23. the center hexagon socket screw C M6 x 12 and replace by an M6 x 60 screw 9 Lift the dosing disc A from the dosing unit housing B by this screw 10 Clean the shear plate using a cotton cloth 11 Clean the dosing hopper and the dosing disc in soapy water 12 The dosing unit housing may also be cleaned with soapy water 13 Ensure that soapy water does not enter ball bearings 14 Dry all parts thoroughly Installing the Dosing Station LI ali W Dasing unit sida view 1 Place the dosing disc in the dosing unit housing 2 Remove the screw M6 x 60 3 Screw the dosing disc in place by means of 2 hexagon socket screws M6 x 30 o N D 0O S Tighten the profile clamp Digital Dosing Units Mount the center hexagon screw M6 x 12 Install the shear plate and then the dosing unit Turn the dosing disc to check for smooth movement Position the dosing hopper on the dosing unit 5 4 Changing the Dosing Disc in the DT Digital Dosing Station Removing the Dosing Disc SCH E Do 6 Empty the dosing station Switch the control unit off by means of the on off switch Dismantle the dosing unit and remove the shear plate Loosen the two hexagon socket screws M6 x 30 on the top side of the dosing disc Loosen the center hexagon socket screw M6 x 12 and replace by a M6 x 60 screw Lift the dosing disc from the dosing unit housing by this screw Installing the Dosi
24. voltage Extruder Follower Interface Signal Converter Isolating power sources and sensor signals is the most effective method for eliminating undesirable ground loop currents and induced electrical noise To determine the correct signal convert to use o Define whether a current mA or voltage dc signal from the extruder is available to utilize o The range should be either be 0 20 mA or 0 10 VDC respectively o The controller has no specific requirement other than the signal being isolated and proportional to the speed of the extruder Signal Converter with AC Power Supply Vendor Phoenix Contact Order Designation MCR FL C UI UI DCI 24 230 Supply Voltage 20V to 253V AC DC Input 4 20 mA 0 10 VDC Quantity 1 Output 0 20 mA 0 10 VDC Quantity 1 Digital Dosing Units 22 Signal Converter with DC Power Supply This module requires a separate 24 VDC power supply Vendor Phoenix Contact Order Designation MCR FL C UI 2UI DCI NC Supply Voltage 20 to 30V DC Input 4 20 mA 0 10V Quantity 1 Output 0 20 mA 0 10V Quantity 2 24 VDC Mini Power Supply A Phoenix Contact power supply for the Phoenix Contact signal conditioner listed above Vendor Phoenix Contact Order Designation MINI PS 100 240AC 24DC 1 Please note that the data given here has been taken from Phoenix Contact s online catalog For comprehensive information and data please refer to the user documentation at http www download phoenixcontact com 3 2
25. 0 65 Kg min 0 22 Ibs min 1 43 Ibs min 128 __ _ _ External run stop signal controls dosing 64 _ Mounting on a Micro mixing hopper nananana aana aeaaea 206 a _ Alarm output switched in case of power failure S12 EXUIUSIOLN MOTE EE 1024 1024 PI le FAVAN 2 DlS a s oi sun yn Sr 2004y seeks 0 WR a NG de Glas 16348 _____ Configuration value s gt s5 454 X n sab Sala Sad eden EEN bees EET 1075 Injection Molding Mark the functions required Use the numerical value indicated and insert it in the empty field if applicable Total the figures for configuration value Optional raw material level probe installed 1 Optional additive level probe installed 0 2 Digital Dosing Units 60 Optional blending mixing unit installed vass 8 Totalizer displayed in Ib kg default arva ves Ip Shot weight 1 kg 6 5 Kg 2 2 lbs 14 3 Ibs 0 _ Shot weight 10 kg 65 ko 22 Ibs 143 Ibs 32 oo Shot weight 0 1 kg 0 65 Kg 0 22 Ibs 1 43 Ibs 128 NOTE The shot weight selections above determine placement of the decimal point on the display External run stop signal controls dosing n naana naaa aeaa 64 Mounting on Micro mixing hopper 00 eee eee 256 Alarm output is switched in case of power failure 512 Blue e
26. Initial Operation The control system is factory programmed Nevertheless specific values need to be predefined or checked prior to operation basic parameter settings The input values will be saved and will still be available if the unit is switched off or a power failure occurs Please refer to Appendix B for these values Extrusion operations require a span factor to be entered into the basic settings Please refer to Appendix B Prior to putting your new Digital Dosing Additive Feeder on line e You must enter a recipe and calibrate the feeder e Recipe parameters are different for Injection Molding Extrusion Constant and Extrusion Proportional operation See each individual section for details e The calibration method is the same for all processes e Once the unit is online recipes can be saved for later recall 10 maximum Digital Dosing Units 23 e This section will show how to calibrate the unit bring the unit on line enter a recipe and store and recall recipes 3 3 Injection Molding During each molding cycle the Digital Dosing unit doses the correct amount of additive evenly throughout the screw recovery cycle The Digital Dosing unit determines the correct amount of additive from the recipe and automatically adjusts the duration and speed of dosing by measuring the molding machine screw recovery time each cycle Recipe Input Injection Molding To enter a recipe for injection molding the following p
27. a gm F Ra throughput of the extruder in dimin of gt Pe or w Ib min e Press again e The machine displays a flashing g or Ib a flashing min and We Digital Dosing Units 34 e After 2 flashes quickly on the display a number in the format xxx xx will come up on the display e Enter the expected extruder throughput during production in grams per minute Or pounds per minute The range of values that can be entered is 001 0 to 6500 grams per minute 00 01 to 14 30 Ib m Step 3 Press ke LED displa displa sgm Ba Band rotational speed of the extruder e Press E a third time e The machine displays a flashing screw MW e After 3 flashes quickly on the display a number in the format xxx xx will come up on the display e Enter the extruder screw speed rom corresponding to the throughput entered in step 2 Step 4 Press ke LED dispa displa dr calibration weight in grams or pounds P Press SCH a fourth time The machine displays a flashing and g After 4 flashes quickly on the screen a number in the format xxx xx will come up on the display Enter the calibration weight in grams If the calibration weight is unknown enter the appropriate value from Section 2 based on your disc size to obtain a starting weight Upon completion of the calibration procedure the calibration weight will automatically be updated into the recipe The range of values that can be en
28. alibration of additive material DD Discs Calibration Number Range DD 30 030672 1 75 DD 30 051818 15 00 DT Discs Calibration Number Range DT 30 101820 DT 30 102025 38 00 DP Discs DT 30 203012 100 00 DT 30 204010 175 00 Calibration Number Range DP 30 050940 17 00 Digital Dosing Units 9 Recipe Setup for Extrusion 1 Turn power switch to ON position 2 Press A Input to display 1 Additive Using arrow keys set additive ratio 3 Press A Input to display 2 Throughput of extruder Using arrow keys set the total extruder throughput in g min or Ib min 4 Press 2 Input to display 3 Extruder screw speed Using arrow keys set the extruder screw speed RPM expected during production NOTE For Extrusion Constant operation the above step will be skipped 5 Press Input to display 4 Calibration weight for additive Enter the appropriate value from the range table on page 9 and proceed to calibration mode below for calibration of additive material Calibration 1 Press Calibration button to start this procedure Display will show 2 Place the plastic calibration cup on the scale and tare so that the weight of the cup approx 24 grams is not calculated in the calibration procedure 3 Remove cover of the calibration box secured by two 5 mm Allen screws under the dosing disc assembly and insert plastic cup provided in top of dosing hopp
29. displayed in Ib kg default j jzjeejl_ 16 Extruder throughput 1 kg 6 5 Kg min 2 2 Ibs min 14 3 Ibs min 0 Extruder throughput 10 kg 65 kg min 22 Ibs min 143 Ibs min DZ ae Extruder throughput 0 1 kg 0 65 Kg min 0 22 Ibs min 1 43 Ibs min 128 NOTE the throughput selections determine placement of the decimal point on the display External run stop signal controls dosing e 064 Mounting on Micro mixing hopper KK KK KK ED O Alarm output is switched in case of power failure s U UUU 512 Extrusion proportional extruder folowe j j hnk w 1024 EUS ENE ee 3072 PrINtGPAVAIADIC 4 6 X525 453 4 4 cl xh Raed EE oo Re ee ae spaden 16348 _____ Configuration value naaa kn kk kk kK kK KK KK KI KK KK KK KK KK KK KK ka k k k k kk ka Example e Level probes raw material and additive probes installed Digital Dosing Units 59 e Throughput 8000 g min e Totalizer displayed in lbs e Extrusion mode Raw material probe 0 0 0 aa ee an 1 1 Adve DI OD Cres uca zk ae hee REG ee bh a ee RES Be 2 2 ABIRAM UML saa sener decease Sade Ph ee oes RASA SAS 8 Totalizer displayed min 16 16 _ Extruder throughput 1 kg 6 5 Kg min 2 2 Ibs min 14 3 Ibs min 0 _ Extruder throughput 10 kg 65 kg min 22 lbs min 143 Ibs min 32 32 Extruder throughput 0 1 kg
30. er 4 Press Run and the dosing disc turns 1 4 turn This fills all pockets of dosing disc Dump the dosed material back into the dosing hopper without weighing and replace plastic cup in calibration box 5 Press Run and the dosing disc turns 1 complete revolution Remove the calibration cup with the material and place on the gram scale Enter the weight on the scale into the controller using the arrow keys Empty and replace calibration Cup 6 Repeat step 5 four more times each time entering the new weight from the scale into the controller using the arrow keys Sometimes the values won t change or sometimes they may only change by a few tenths of a gram The controller keeps a running average of all calibration weights entered Digital Dosing Units 10 f After all five samples have been completed press run once more and this will save the calibration weight of the material to the recipe The calibration light will go out and the screen will now show the total amount of additive dosed The Digital Dosing feeder is now ready to begin operation 8 Please refer to Operation Manual for all supplementary information regarding general operation cleaning maintenance and troubleshooting 9 Make sure that there is a virgin material supply setup to begin processing If you do not have a loader or hopper for the virgin material or if any of the above procedures did not work properly please contact ACS Technica
31. he total is the Software Setup Factor A 4 Recipe Formulas The following formulas can be used to determine if a recipe is appropriate or possible Injection Molding For injection molding applications compute the dosing disc speed and total number of disc revolutions using the following formulas Recipe limitations are listed in the table following the equations Disc RPM n Yan 8 x Additive x Ee Disc Calibration Weight g x Recovery Time s Shot Weight g x Additive x 0 01 Disc Revolutions per Shot l Disc Calibration Weight g Recipe Limitations for Injection Molding Motor Assembly Speed rpm Maximum Speed rpm Number of Disc Revolutions __ rDTrnj_ _ Ii Zi_5k k A6 Digital Dosing Units 56 Extrusion For extrusion applications compute the dosing disc speed using the following formula Recipe limitations are listed in the table following the recipe Additive x Total Extruder Throughput Ib hr 13 22 x Disc Calibration Weight g Disc RPM Recipe Limitations Extrusion Motor Assembly Speed RPM Maximum Speed RPM Digital Dosing Units Sy Appendix B Basic Parameter Settings Extrusion Mode You need an extruder signal that is proportional to the extruder speed to operate in the Extrusion Proportional mode You can use any of the following e Frequency signal must be 12 VDC square wave e 0 10 VDC signal e 0 20 mA current signal Determi
32. hout weighing This sample is used only to ensure that all disc pockets are completely filled e Replace container in calibration box or under material outlet tube Step 3 Press ke LED displa displa If calibration weight 0 in the recipe The dosing motor turns for one revolution Run es al half of the maximum rotational speed e Press KA to take a sample for weighing e The disc will rotate one full revolution After the disc has stopped rotating a number in the format xx xx will appear on the screen along with a flashing and g Step 4 Press ke LED displa displa proportioning and entry of the weight e Enter the weight in grams using the Arrow Keys Ka EC e Empty and replace weighing container in calibration box or under material outlet tube Step 5 e Repeat steps 3 and 4 four 4 more times e Notice that the displayed calibration weight may change after each sample weight is entered e The value is an average of all the weights entered No calculations are required It can happen that the calculated speed is either too high or low causing alarm A0009 Check the recipe and settings and modify if necessary Digital Dosing Units 39 Step 6 After the fifth calibration sample press RUN the controller will automatically finish the calibration cycle and be ready to run The following are methods used to interrupt the calibration cycle terminate proportioning while not taking Gi o
33. igital Dosing unit is dosing material 3 To stop the dosing process while the extruder is operating press Q The Digital Dosing unit will automatically stop dosing when the extruder stops While the unit is dosing depending on software revision the current recipe can be viewed but not modified by pressing a In some software versions the percent additive can be changed while the unit is dosing NOTE See Appendix A Troubleshooting for information on problems or errors encountered and their resolution Digital Dosing Units 33 3 5 Extrusion Proportional Extruder Follower Option Recipe Input Extrusion Proportional To enter a recipe for Extrusion Proportional the following process data is required e Percentage of additive e Expected throughput of the extruder during production e Extruder screw speed during production e Calibration weight in grams Step 1 Press ke LED displa displa qe lt gt wi parts of the additive colouring in e Press the Input key Veen ONCE e The symbol flashes e After 1 flashes quickly on the display a number in the format xxx xx will come up on the display e Enter the additive percentage by using the Arrow Keys Ka A AN The range of values that can be entered is 0 01 to 50 00 The arrow keys are used to change all process variables The double arrow key allows the user to ramp up or down at a faster rate Step 2 Press ke LED displa displ
34. l Support 800 423 3183 8 AM 5 PM CST Digital Dosing Units 11 Basic Input Parameters for Digital Dosing Feeder with Injection Software P1 _ Older units or P2 _ _ newer units Hold Stop and Input buttons until 7 flashes 2 gt Js Enter the input number for the specific motor from the table below This value sets the impulses of the encoder Manufacturer Motor Color RPM Input Number Bauer Blue 6 4 11739 Bauer Blue 11 5 6600 Bauer Blue 35 5 2135 Bison Black 2 65000 Bison Bison Bison Black Black Black 6 12 38 25200 14103 4387 A o Press Input button When 8 flashes enter 0 7 for Blue Bauer motor Or enter 0 5 for the black Bison or Colorblend S motor This value sets the nominal current for the motor 3 b gt put 7 Digital Dosing Units 12 Press Input button When 9 flashes enter the configuration value Please see the list Determining Configuration Value for more information E eli FIAs APSE FEAL Press Input button When 10 flashes enter 1 if a blue Bauer motor is intended for use If any another motor is intended for use enter 0 H r BAA Aer HAMA Digital Dosing Units 13 Press Input button When 11 flashes enter 50 This value is the minimum input frequency Gti Clg Press Input button When 12 flashes enter 5 56 This value is the spa
35. libration 7 3 grams rev Weight Per Disc 35 Ibs cu ft Min Throughput with 100 Continuous Running 35 Ibs cu ft 0 04 Ib hr 0 02 kg hr 0 10 Ib hr 0 045 kg hr 0 19 Ib hr 0 09 kg hr 0 11 lb hr 0 05 kg hr 0 27 Ib hr 0 12 kg hr 0 55 Ib hr 0 25 kg hr 0 20 Ib hr 0 09 kg hr 0 48 Ib hr 0 22 kg hr 1 00 Ib hr 0 44 kg hr 63 Max Throughput with 100 Continuous Running 35 Ibs cu ft 1 30 Ibs hr 0 59 kg hr 2 32 Ibs hr 1 05 kgs hr 7 16 Ibs hr 3 25 kgs hr 3 59 Ibs hr 1 63 kgs hr 6 33 Ibs hr 2 87 kgs hr 19 80 Ibs hr 9 00 kgs hr 6 23 Ibs hr 2 83 kgs h 11 0 Ibs hr 4 99 kgs hr 34 60 Ibs hr 15 70 kgs hr Weight Per Disc Revolution 44 Ibs cu ft 1 95 g rev 0 027 g hole 5 39g rev 0 13 g hole 9 38g rev 0 38 g hole Min Throughput with 100 Continuous Running 44 Ibs cu ft 0 041b hr 0 02 kg h 0 12 Ib hr 0 05 kg hr 0 26 Ib hr 0 12 kg hr 0 15 Ib hr 0 07kg h 0 35 Ib hr 0 15 kg hr 0 70 Ib hr 0 32 kg hr 0 24 Ib hr 0 11 kg h 0 61 Ib hr 0 27 kg hr 1 25 Ib hr 0 57 kg hr Max Throughput with 100 Continuous Running 44 Ibs cu ft 1 65 Ib hr 0 75 kg h 2 89 Ib hr 1 31 kg hr 9 00 Ib hr 4 10 kg hr 4 56 Ib hr 2 07 kg h 8 00 Ib hr 3 62 kg hr 25 30 Ib hr 11 50 kg hr 7 90 Ib hr 3 60 kg h 14 0 Ib hr 6 36 kg hr 44 Ibs hr 20 kosher DD30 051818 ae
36. n factor er 2 e er Press Input button When 13 flashes enter the communication address lf Euromap17 is not intended to for use enter 0 This value is the communication address Only enter a value here if Euromap1 7 report is in use inpast Her Zeit Digital Dosing Units 14 Press Input button When 14 flashes enter 220 This value is for the material contents of the mixing hopper Only in case of mounting on a micro mixing hopper Press Stop to exit parameters 18 will flash then it automatically returns to the totalizer screen Digital Dosing Units 15 Basic Input Parameters for Colorblend C 150 with Extrusion Software E1 _ Older units or EZ _ newer units Hold Stop and Input buttons until 7 flashes 2 gt Js Enter the input number for the specific motor from the table below This value sets the impulses of the encoder Manufacturer Motor Color RPM Input Number Bauer Bauer Bauer Bison Bison Bison Bison Blue Blue Blue Black Black Black Black 6 4 11 5 35 9 2 6 12 38 11739 6600 2135 65000 25200 14103 4387 Press Input button When 8 flashes enter 0 7 for blue Bauer motor Or enter 0 5 for the black Bison or Colorblend S motor This value sets the nominal current for the motor Digital Dosing Units 16 Press Input button When 9 fla
37. n of both units Figure 1 Single Station Digital Dosing Unit Shown with optional virgin supply hopper and controller mounting plate Digital Dosing Units 3 Figure 2 Dual Station Digital Dosing Unit Shown with optional virgin supply hopper and controller mounting plate Digital Dosing Units 4 1 1 Controller The Digital Dosing additive feeder consists of a controller s dosing motor s and feeder s The controller is used to e Configure the unit to the desired process e Calibrate the feeder e Run monitor and stop the dosing process e Enter recall and run recipes e Troubleshoot problems via error codes A keypad and LED display see Figure 3 are used to enter or change data e The control system is switched on position 1 with the On Off switch A e The control system is operated through the keypad B e The individual operating modes are indicated by symbols C e Messages appear on a 5 digit LED display D Figure 3 Keypad and LED Display Digital Dosing Units 5 1 2 Keys and Symbols B S S lt gt a Recipe Storage Recall For saving recalling or modifying recipes Stop Stops the continuous operation of the feeder Will reset the totalizer showing metered amount of additive to zero if depressed for two seconds Up arrow For increasing the set value in decimal increments Down arrow For decreasing the set value in decimal increments Arrow Key For fast inc
38. n the calibration weight Lat or terminate proportioning while taking on pe the calibration weight Press ke LED displa displa e Pressing the stop button will stop proportioning and not accept the calibration weight e Pressing the calibration button will stop proportioning and accept the calibration weight NOTE It is normal for calibration weights to vary slightly from sample to sample Digital Dosing Units 40 Section 4 Advanced Operations Control Functions 4 1 Recipe Storage and Recall A maximum of ten 10 recipes can be stored and retrieved with the Digital Dosing controller in the Recipe Storage Recall mode Recipes are stored using a two digit identification number Pressing Qi at any time will exit the Recipe Storage Recall mode Recipe Storage To store the current recipe Press ke LED displa displa Li load and the mostrecenty called up recipe number CH o save and the most recently saved el recipe number Step 1 Ve e Press the Recipe Storage Recall key Cty A two digit number 01 through 10 will appear on the screen This is the recipe I D number Step 2 e Use the Arrow keys vV YA IN to select the desired recipe number NOTE A new recipe stored under the ID number of an existing recipe will overwrite the existing recipe number without warning Digital Dosing Units 41 Step 3 Press ke LED displa displa gt Oe i save recipe e
39. ne the frequency output in the lower working area A of the extruder Record the data Min input frequency Hz Determine the frequency output in the upper working area B of the extruder Record the data Hz lV mA Max input frequency Hz If a voltage signal is available 0 10 VDC calculate the frequency output of the extruder for the lower upper working area using the formula Frequency Hz Input voltage V x 10000 Hz 10 V Note the data Min input frequency Max input frequency Hz Hz lf a current signal is available 0 20 mA calculate the frequency output of the extruder for the lower upper working area using the formula Digital Dosing Units 58 Frequency Hz Input current mA x 10000 Hz 20 mA Note the data Min input frequency Hz Max input frequency Hz Calculate the span factor using the formula Span factor Hz rom Frequency Hz Rotational speed of the extruder rpm x 10 Note the data Span factor Determining the Configuration Value Extrusion Constant or Proportional Mark the functions required Use the numerical value indicated and insert it in the empty field if applicable Total the figures for configuration value Optional raw material level probe installed j j j 1 Optional additive level probe installed ua lk vr vr vr vr reg Optional blending unit installed kk KK KII KI va ek A O Totalizer
40. ng Disc 2 Change and place the dosing disc in the dosing unit housing Remove the screw M6 x 60 Screw the dosing disc in place by means of 2 hexagon socket screws M6 x 30 Mount the center hexagon socket screw M6 x 12 Install the shear plate and then the dosing unit Turn the dosing disc to check for smooth movement Position the dosing hopper on the dosing unit Tighten the profile clamp See Appendix D Spare Parts List on page 61 for disc part numbers Digital Dosing Units 49 Installing Different Types of Dosing Discs Dosing discs of the same type and thickness 72 pocket may be exchanged for each other without any problems If dosing discs with a different compartment number or thickness are installed this has to be entered in the control system DD Discs Calibration Number of Number pockets DD 30 051818 15 00 f2 DD 30 051040 5 00 40 5 18 1 Enter the preliminary calibration value of the newly installed dosing disc 2 Execute calibration to determine the final calibration value 5 5 Removing Replacing the Wiper in the DT Dosing Station 1 Empty the dosing station 2 Open the profile clamp C of the dosing container 3 Remove the profile clamp C A 4 Remove the dosing container B along with the dosing hopper A 5 Loosen the 3 plastic screws on the wiper 6 Remove the wiper and holding plate 7 Install the new wiper along with SE the holding
41. of the dosing motor Dosing motor defective or jammed 100 see name plate is being Check the dosing motor and exchange it exceeded for more than 2 seconds by if necessary Check whether the dosing 30 or for a maximum of 0 5 seconds disc is jammed by material and remove by 80 the material if necessary The nominal current of the dosing motor Dosing motor defective or jammed 100 see name plate is being Check the dosing motor and exchange it exceeded for more than one minute if necessary Check whether the dosing disc is jammed by material and remove the material if necessary A004 Excess temperature The temperature Check whether the cooling plate at the within the controller housing is gt 85 C back of the controller is sufficiently cooled down Use fan if necessary A005 The encoder pulse generator does not If dosing motor does not turn check emit any pulses for approximately 2 whether the dosing disc is jammed by seconds material and remove the material if necessary If disc is free check the dosing motor exchange if necessary If motor operates but alarm persists check speed encoder output Replace as necessary Defect at the dosing motor Check dosing motor exchange if necessary Check whether the dosing disc is jammed by material and remove the material if necessary Power supply part or control out of order Manufacturer Service A007 Dosing motor stops or doesn t work Brake at the dosing motor out of
42. order Control system out of order Manufacturer service A008 The screw retract time of the processing The unit cannot be operated in machine is shorter than 0 1 seconds combination with this processing machine A009 The calculated speed of the motor is Check basic parameter settings and either too high or too low recipe modify if necessary May require changing to different sized dosing disc A0010 The feed station is not able to meter the Check basic parameter setting and desired recipe recipe modify if necessary May require changing to different sized dosing disc A0011 The raw material probe is not covered Refill Material A0012 The additive probe is not covered Refill material A0014 Power failure interrupted run cycle Clear alarm after power restored programmed unit Service A003 A006 For approximately 4 seconds there is a deviation of the motor speed of more than 20 from the nominal rotational speed Digital Dosing Units 53 A 3 Determining the Software Setup Factor The Digital Dosing control unit is configured via a Software Setup Factor binary code To determine the Software Setup Factor answer the following questions If the answer is yes enter the code number in the selection column If the answer is no enter 0 in the selection column When all the questions have been answered and the selection column is completed add up the total for the selection column T
43. pe Dosing unit side view fasteners 5 Open the toggle type fasteners on the dosing motor Digital Dosing Units 46 6 Remove the dosing unit from the dosing motor 7 Remove the cover from the connecting piece D 8 Loosen the two screws C on the underside of the dosing unit housing E 9 Remove the shear plate A Installing the shear plate 1 Place the new shear plate in the dosing unit housing 2 Ensure that the shear plate is positioned correctly 3 Screw the shear plate in place by means of 2 hexagon socket screws M5 x 16 4 Turn the dosing disc to check for smooth movement 5 Mount the cover on the connecting piece 6 Position the dosing unit on the dosing motor note guide pins 7 Close the toggle type fasteners on the dosing motor 8 Mount the safety screws 9 Position the dosing hopper on the dosing unit 10 Mount the profile clamp 11 Mount the screw at the profile clamp 5 3 Cleaning the DD Digital Dosing Station Dismantling the Dosing Station 1 Empty the dosing station 2 Switch the control unit off by means of the on off switch 3 Disconnect from main voltage 4 Open the profile clamp on the dosing hopper Doting unit flop view Digital Dosing Units 47 5 Remove the dosing hopper from the dosing unit 6 Dismantle the dosing unit and remove the shear plate D f Loosen the two hexagon socket screws B M6 x 30 on the top side of the dosing disc A 8 Loosen
44. placement or service v Power source 110 or 220 volt single phase 50 or 60 hertz verify voltage on Serial Number tag M Proper mounting flange adapter for the feed throat M Dry ZERO VOLTAGE contact that closes during screw recovery of IMM M Gram scale to measure weight of additive material for calibration Mounting d Mount the complete unit including dosing hopper full of material on the feed throat may need an adapter for feed throat 2 Identify the motor drive connector Amp connector black and connect to motor 3 Identify the communication cable DB 9 plug silver and connect to DB 9 connector under motor drive assembly Identify power cord and plug into appropriate outlet 5 INJECTION MOLDING Identify the cycle run cable 2 conductor cable gray for connection to a dry ZERO VOLTAGE contact that closes during the screw recovery cycle of the molding machine EXTRUSION Identify the input cable 2 conductor cable gray for connection to 0 10 VDC or 0 20 mA signal that indicates speed rpm of the extruder Digital Dosing Units 8 Recipe Setup for Injection Molding 1 Turn power switch to ON position 2 Press Input 2 to display 1 Additive Using arrow keys set additive ratio screw recovery time in seconds 5 Press Input to display 4 Calibration weight for additive Enter the appropriate value from the range table below and proceed to calibration mode below for c
45. r parameters no printing 1 printing setpoints 2 printing parameters 3 page change 4 printing each event 5 printing alarms will be displayed e After the 6 flashes on the screen a number in the format xxx xx will come up on the display e By using the arrow keys you can choose your printer parameters If you have not activated this option skip to the next step Digital Dosing Units 31 Step 6 Press ke LED displa displa lt gt total throughput in kg put 6 Press E again 7 The number 18 will be displayed before the total throughput in kg is displayed Digital Dosing Units 32 Operation Extrusion Constant 1 Ensure that the unit is properly installed Section 3 1 a recipe is entered Section 3 4 1 and the feeder is calibrated Section 3 6 before attempting to begin operation If desired clear the totalizer by pressing 2 continuously for 5 seconds until the display is reset to 00 00 fs Place the Digital Dosing unit into operation by pressing EE The green LED will light when the unit is ready to dose but the Digital Dosing unit will not feed until the extruder begins operation Start the extruder The Digital Dosing unit will begin dosing material as soon as the extruder starts If the unit is installed properly the process machine symbol We will light on the controller when the extruder starts The disc symbol will light when the D
46. reasing decreasing of the set value in larger increments Must be pressed simultaneously with the up or down arrow Run Starts the continuous operation LED is lit up or calibration mode LED flashes Calibration Key Switches from operation to calibration mode LED flashes when calibration process has started Input Selects the next screen for the input of program parameters Digital Dosing Units 6 op lt 3 CH Q T Lights when the run signal from the process machine is received by the Digital Dosing controller During operation lights when the disc is dosing material During calibration and recipe input viewing lights when a calibration weight is input or viewed EXTRUSION ONLY Lights when a screw speed signal is received from the extruder during proportional extrusion control tracking or following Lights when an alarm occurs Percent additive Kilograms Grams Pounds Minutes Seconds SEL EEE E e lr Digital Dosing Units d Section 2 Quick Start u Quick Start is intended to help you in starting up your Digital Dosing feeder quickly and easily Please refer to the manual to go into greater detail Unpacking 1 Unpack box making sure all parts indicated on packing list are included 2 Check all parts and equipment for any damage sustained during shipment 3 4 Make sure the following are present before proceeding If any damage is noted contact manufacturer for re
47. rocess data is required e Percentage of additive e Total shot weight in grams includes parts and runner system e Screw recovery time of the machine in seconds e Calibration weight in grams e Step 1 Press ke LED displa displa I TI parts of the additive colouring in input e The LED symbol flashes e 1 will quickly flash on the display before a number in the format xxx xx comes up on the display e Enter the additive percentage by using the Arrow Keys Ka YA N The range of values that can be entered is 0 01 to 50 00 The arrow keys are used to change all process variables The double arrow key allows the user to ramp up or down by larger increments Digital Dosing Units 24 Step 2 Press ke LED displa displa Step 3 Press ke Fe tm i Z shot weight in g or Ib aspectively Press Input 2 again The symbols g or Ib min and the screw symbol flash After the 2 quickly flashes on the display a number in the format xx xxx will come up on the display Enter the shot weight using the arrow keys The range of values that can be entered is 001 0 to 6500 grams 0 01 to 14 30 pounds LED displa displa 3 screw recovery time in seconds Press Input 2 a third time The screw and s symbols flash After 3 flashes quickly on the display a number in the format xxx xx will come up on the display Enter the
48. shes enter the configuration value Please see the list Determining Configuration Value for more information E eli WMS APSE FEAL Press Input button When 10 flashes enter 1 if a blue Bauer motor is intended for use If any another motor is intended for use enter 0 Zeg Ka on Ea l RIJE EI NL MAME Digital Dosing Units 17 Press Input button When 11 flashes enter 50 This value is the minimum input frequency Gti gt lt br Press Input button When 12 flashes enter 10 This value is the span factor lt Fn e fa Ze wl s Press Input button When 13 flashes enter the communication address lf Euromap17 is not intended to for use enter 0 This value is the communication address Only enter a value here if Euromap1 7 report is in use Digital Dosing Units 18 Press Input button When 14 flashes enter 220 This value is for the material content of the mixing hopper Only in case of mounting on a micro mixing hopper Press Stop to exit parameters 18 will flash then it automatically returns to the totalizer Screen Digital Dosing Units 19 Section 3 Initial Installation and Operation 3 1 Initial Installation Hopper Piece Pracessing Maghine EEE Direction of Material Flow Figure 4 Digital Dosing Unit Assembly 1 The Digital Dosing additive feeder is not
49. skip to the next step Digital Dosing Units 36 Step 7 e Press e a fifth time to return to the totalizer Operation Extrusion Proportional Extruder Follower Option M Ensure that the unit is properly installed Section 3 1 M A recipe is entered Recipe Input Extrusion Proportional Section M The feeder is calibrated Section 3 6 before attempting to begin operations 1 If desired clear the totalizer by pressing H continuously for 5 seconds until the display is reset to 00 00 2 Place the Digital Dosing unit into operation by pressing the Run key Var The green LED will light when the unit is ready to dose but will not feed until the extruder begins operation 3 Start the extruder The Digital Dosing unit will begin dosing material as soon as the extruder starts If the unit is installed properly the process machine symbol me will light on the controller when the extruder starts The disc symbol will light when the Digital Dosing is dosing material 4 To stop the dosing process while the extruder is operating press KM The Digital Dosing unit will automatically stop dosing when the extruder stops 5 While the unit is dosing depending on software revision the current recipe can be viewed but not modified by pressing EH In some software versions the percent additive can be changed while the unit is dosing The actual extruder screw speed will be displayed in the third recipe regi
50. ster Digital Dosing Units 21 3 6 Calibration All feeders must be calibrated before any blending recipes can run using the Digital Dosing additive feeder NOTE The calibration weight metered material weight for one revolution of the dosing disc must be determined separately for each material to be dosed since calibration weight differs from material to material The following equipment is needed for calculating the calibration weight e Scale with a minimum accuracy of 0 01 grams e The weighing container which is included in the equipment delivery Follow these procedures 1 Remove one of the square covers and insert the calibration container provided 2 Fill the dosing hopper with a minimum of six 6 inches of material 3 Note weight of weighing container tare weight or tare scale to zero NOTE The Digital Dosing station may only be operated if all sample chutes are in place or a collecting bin is in the calibration box Determining the Calibration Weight Step 1 Press ke LED display displa Te Pe e To start the calibration process press the calibration key Step 2 Press ke LED displa displa filling procedure A e e Once the sample container is in position press Dul e The disc will rotate 1 4 revolution and dispense material into the sample container After the disc stops the screen will remain blank Digital Dosing Units 38 e This sample should be returned to the material hopper wit
51. switching sensitivity turning it to the right increases the switching sensitivity 5 Fill the dosing station until the level probe is two thirds covered The yellow control lamp should now switch on again If not repeat Step 4 6 Reinstall the plastic screw M3 NOTE The sliding switch under the cover must be set on 0 Communication Protocol Interfaces The Digital Dosing unit can be controlled remotely through the EUROMAP E17 or MODBUS RTU protocol Contact Sales and Service concerning this option at 810 720 7300 Digital Dosing Units 45 Section 5 Maintenance 5 1 Maintenance Intervals Check warning signs on equipment for good legibility Daily and completeness Weekly Check function of the On Off Switch Check shear plate in DD dosing station and wiper in Every 3 months DT dosing station Check that all electrical and mechanical connections Every 6 are tight months Check adjustment of the level probes optional Annually Check dosing disc in dosing station DD DT Each time Clean the dosing station after Check shear plate or wiper material Is changed Check dosing disc 5 2 Removing the Shear plate DD feeder only Removing the shear plate 1 Empty the dosing station 2 Open the profile clamp TT Tan B on the dosing Ss He hopper p nll Jr 3 Remove the dosing hopper from the dosing unit 4 Open the safety screws at the toggle ty
52. tered in this field is 00 00 to 400 0 Digital Dosing Units 35 Please note Parameters 5 and 6 will only be displayed when a mixer and or a printer is configured Step 5 Press ke LED displa displa Er n maintained running time of the blending unit in seconds pui e Press 2 again and the symbol s will light up and the number 5 will be displayed if you have a blending unit and have invoked this option e After 5 flashes on the display a number in the format xxx xx will come up on the display e Enter the maintained running time of the blending unit in seconds using the arrow keys This is how long the blender will run after each dosing cycle and should be adjusted for the best possible blend Too little time may not produce good dispersion too much time can cause separation especially with heavy concentrates Step 6 Press ke LED displa displa he Ka printer mpu Only if a printer optional is available enter printer parameters no printing 1 printing setpoints 2 printing parameters 3 page change 4 printing each event 5 printing alarms e Press Qn again This will activate the printing option if it is available and the number will be displayed e After the 6 flashes on the screen a number in the format xxx xx will come up on the display e By using the arrow keys you can choose your printer parameters If you have not activated this option
53. the process speed then the Digital Dosing unit must be configured for Extrusion Proportional operation go to Section 3 5 Recipe Input Extrusion Constant To enter a recipe for Extrusion Constant the following process data is required e Percentage of additive e Total throughput rate of the extruder during production e Calibration weight in grams e Step 1 Press ke LED displa displa ge bw lt gt wi parts of the additive colouring in Ira e Press 2 once e e The symbol will flash e After 1 flashes on the screen a number in the format xxx xx will come up on the display Digital Dosing Units 29 e Enter the additive percentage by using the Arrow Keys Ww Kee A The range of values that can be entered is 0 01 to 50 00 The arrow keys are used to change all process variables The double arrow key allows the user to ramp up or down at a faster rate Step 2 Press ke LED displa displa or throughput of the extruder in dimir or D e Press 2 again e The symbols g or Ib min and we flash e After 2 flashes quickly on the display a number in the format xxx xx will come up on the display e Enter the total extruder throughput in grams per minute or pounds per minute The range of values that can be entered is 001 0 to 6500 grams per minute 00 01 to 14 30 lb m Extrusion Constant parameter 3 is skipped Step 3 Press ke LED displa displa dr
54. thin two conductor cable to a set of DRY NO VOLTAGE contacts that CLOSE when the screw rotates See Figure 5 for electrical diagram Extrusion Proportional Wire the cycle run slave cable to the extruder signal output that is proportional to the extruder speed The signal output can be one of the following 0 10 VDC or 0 20 mA Please refer to the labels on the cycle run slave cable for the correct input to avoid damaging the controller Digital Dosing Additive Feeder should be configured from the factory for each specific input See Figure 6 for analog inputs Voltage from Extruder needs to be isolated Consult factory for other signal requirements External signal converter may be required Zero input corresponds to zero screw speed and no additive dosing Maximum input corresponds to maximum screw speed If a 0 10 kHz frequency input Is used it must be a square wave width and an amplitude of 12 VDC The shape of the signal is important especially above 7 000 Hz Digital Dosing Units 21 0 10 VDC or 0 20 mA Extruder output Digital Dosing controller diagram of analog inputs Figure 6 Analog Inputs 5 Make sure the unit is turned OFF before plugging it in The switch toward the rear of the controller unit should be in the OFF or O position Standard operation voltage is 110 or 220 VAG 50 60 Hz single phase power Special voltages are available refer to voltage label on the feeder to determine the correct operating
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