Benutzeranleitung / Produktwartung 882 00276.00 des Produzenten Sterling Plumbing
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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: _________________________ .
Digital Dosing Units 2 Table of Contents SECTION 1: INTRODUCTION ……………. ……………………….………............ .............3 1.1 C150 Co ntroller... ................................................................................
Digital Dosing Units 3 Section 1: Introduction This User’s Manual is intended for use with t he Digital Dosing Disc Additive Feeder. The feeder precisely meters and controls the addition of master batches, chemical additives, and regrinds to primary plastics.
Digital Dosing Units 4 Figure 2. Dual Stati on Digital Dosing Unit (Shown with optional virgin supply hopper and controller mounting plate).
Digital Dosing Units 5 1.1 Controller The Digital Dosing additive feeder consists of a controller(s), dosing mo tor(s), and feeder(s). The controller is used to: • Configure the unit to the desired process.
Digital Dosing Units 6 1.2 Keys and Symbols Recipe Storage/Recall: For saving, recalling or modifying recipes. Stop : Stops the continuous operation of t he feeder. Will reset the totalizer showing metered amount of additive to zero if depressed for two seconds.
Digital Dosing Units 7 Symbols Lights when the run signal from the proc ess 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 calibra tion weight is input or viewed.
Digital Dosing Units 8 Section 2: Quick Start-up Quick Start is intended to help you in starting up your Digita l Dosing feeder quickly and easily. Please refer to the manua l to go into greater detail. Unpacking: 1. Unpack box, making sure all parts indicated on packing list are included.
Digital Dosing Units 9 Recipe Setup for Injection Molding: 1. Turn power switch to ON position. 2. Press Input to display # 1, “Additive %”. Us ing arrow keys, set additive ratio.
Digital Dosing Units 10 Recipe Setup for Extrusion: 1. Turn power switch to ON position. 2. Press Input to display # 1, “A dditive %”. Using arrow ke ys, set additive ratio. 3. Press Input to display # 2, “Throughput of extruder”. Using arrow keys, set the total extruder throughput in g/min or lb/min.
Digital Dosing Units 11 7. After all five samples have been complet ed; 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 tota l amount of additive dosed.
Digital Dosing Units 12 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 - Enter the input number for the s pecific motor from the table below.
Digital Dosing Units 13 Press Input button -When “9” flashes, enter t he configuration value. - Please see the list: “Determining Configuration Value” for more information. Press Input button - When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
Digital Dosing Units 14 Press Input button - When “11” flashes, enter 50 - This value is the minimum input frequency. Press Input button − When “12” flashes, enter 5.56 − This value is the span factor. Press Input button − When “13” flashes, enter the communication address .
Digital Dosing Units 15 Press Input button − When “14” flashes, enter 220 − This value is for the materi al contents of the mixing hopper. − Only in case of mounting on a micro mixing-hopper.
Digital Dosing Units 16 Basic Input Parameters for Colorblend C-150 with Extrusion Software (E1._ _ - Older units) or (E2._ _ - newer units) Hold Stop and Input buttons until “7” flashes - Enter the input number for the s pecific motor from the table below.
Digital Dosing Units 17 Press Input button - When “9” flashes, enter t he configuration value. - Please see the list: “Determining Configuration Value” for more information. Press Input button - When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
Digital Dosing Units 18 Press Input button - When “11” flashes, enter 50 - This value is the minimum input frequency. Press Input button − When “12” flashes, enter 10 − This value is the span factor. Press Input button − When “13” flashes, enter the communication address .
Digital Dosing Units 19 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 20 Section 3: Initial Installation and Operation 3.1 Initial Inst allation Direction of Material Flow Hopper Piece Processing Machine Figure 4.
Digital Dosing Units 21 4. Electrical connection to process machine: • 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 Fi gure 5, electrical diagram.
Digital Dosing Units 22 J12-4 _ J12-3 + 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 tur ned OFF before plugging it in. T he switch toward the rear of the controller unit should be in the OFF, or “O” position.
Digital Dosing Units 23 Signal Converter with DC Power Suppl y This module requires a separ ate 24 VDC power supply. Vendor: Phoenix Contact Order Designation: M CR-FL-C-UI-2UI-DCI-NC Supply Voltage: .
Digital Dosing Units 24 • 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.
Digital Dosing Units 25 Step 2: • Press Input again. • The symbols “ g ,” or “ lb ”, “ 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.
Digital Dosing Units 26 Step 4: “ 4 “ = calibration weight in grams or pounds • Press Input a fourth time. • The symbols “ g ” or “ lb ”and flash. • After “4” quickly fl ashes on the screen, a number in the format xxxx.x will come up on the display.
Digital Dosing Units 27 Step 6: • Pressing again, will activate the printing option if it is available . • After the “6” flashes on t he screen, a number in the fo rmat xxx.xx will come up on the display. • By using the arrow keys, you can choose your printer parameters.
Digital Dosing Units 28 Operation - Injection Molding 1. Ensure that the unit is properly inst alled (Section 3.1), a recipe is entered (section 3.3.1), and the feeder is calibrat ed (Section 3.
Digital Dosing Units 29 • To stop the dosing process, press . • While the unit is dosing, the current recipe can be viewed, but not modified by pressing . The recovery time displayed in the curr ent recipe is the average of the last five shots measured from the molding machine.
Digital Dosing Units 30 • Enter the additive percentage by using the Arrow Keys . The range of values that can be entered is 0.01 to 50.00%. The arrow keys are used to change all process variables. T he double arrow key allows the user to ramp up or down at a faster rate.
Digital Dosing Units 31 Step 4: • 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 . • After “5” flashes on the display, a number in the format xxx.
Digital Dosing Units 32 Step 6: 6. Press again. 7. The number “18” will be displayed before t he total throughput in kg is displayed ..
Digital Dosing Units 33 Operation – Extrusion - Constant 1. Ensure that the unit is properly installed (Section 3.1) , a recipe is entered (Section 3.
Digital Dosing Units 34 3.5 Extrusion – Proportional (Extruder Follower Option ) Recipe Input – Extrusion Proportional To enter a recipe for Extrusion Proportional, the following process data is r.
Digital Dosing Units 35 • After “2” flashes quickly on the display, a number in th e format xxx.xx will come up on the display. • 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.
Digital Dosing Units 36 Please note: Parameters 5 and 6 will onl y be displayed when a mixer and or a printer is configured . Step 5: • 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 .
Digital Dosing Units 37 Step 7: • Press a fifth time to retu rn to the totalizer. Operation – Extrusion – Proportional (Extruder Follower Option ) ; Ensure that the unit is proper ly installed (Section 3.1) ; A recipe is entered (“Recipe Input -Extrusion Proportional” Section ) ; The feeder is calibrated (Section 3.
Digital Dosing Units 38 3.6 Calibration All feeders must be calibrated before any blendi ng recipes can run using the Digital Dosing additive feeder. NOTE: The calibration weight (metered ma terial we.
Digital Dosing Units 39 • This sample should be returned to th e material hopper without weighing . This sample is used only to ensure that all disc pockets are completely filled. • Replace container in calibration box (or under materi al outlet tube) Step 3: • Press to take a sample for weighing.
Digital Dosing Units 40 Step 6: After the fifth calibration sample press “ RUN “ the controller will automatically finish the calibration cycle a nd be ready to run. The following are methods used to interrupt the calibration cy cle. • Pressing the stop button will stop proportioning and not accept the calibration weight.
Digital Dosing Units 41 Section 4: Advanced Operations/ Control Functions 4.1 Recipe S torage 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.
Digital Dosing Units 42 Step 3: • Press and hold the button until the totalizer display returns to the screen. • The recipe is now stored under the selected ID number. Recipe Recall Step 1: • Press the stop button to st op any current applications.
Digital Dosing Units 43 Step 4: • Press and hold until the totalizer appears on the screen. • The recipe is now active and can be run or edited. NOTE: The recalled recipe now becomes the active recipe. 4.2 Clearing the T ot alizer • The totalizer displays the total amount of additive dosed since the last time the totalizer was cleared.
Digital Dosing Units 44 4.4 Optional Equipment, Level Switches and Communications Options Optional equipment for the Digital Dosing Additive Feeder includes: Alarms Several alarm options are availa ble for the Digital Dosing feede r. The standard unit comes with a flashing alarm symbol on the faceplate.
Digital Dosing Units 45 NOTE: Turning the trim-pot to the left decreases the 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.
Digital Dosing Units 46 Figure Section 5: Maintenance 5.1 Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the “On/Off” Switch. Every 3 months: Check shear plate in “DD” dos ing station, and wiper in “DT” dosing station.
Digital Dosing Units 47 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.
Digital Dosing Units 48 5. Remove the dosing h opper from the dosing unit. 6. Dismantle the dosing unit and remove the shear plate (D). 7. Loosen the two hexagon socket screws (B, M6 x 30) on the t op side of the dosing disc (A). 8. Loosen the center hexagon socket screw (C , M6 x 12) and replace by an M6 x 60 screw.
Digital Dosing Units 49 5.4 Changing the Dosing Disc in the “DT” Digit al Dosing S t ation Removing the Dosing Disc 1. Empty the dos ing station. 2. Switch the control unit off by means of the on/off switch . 3. Dismantle the dosing unit and remove the shear plate.
Digital Dosing Units 50 Installing Different Types of Dosing Discs Dosing discs of the same type, and thicknes s (72 pocket), may be ex changed for each other without any problems.
Digital Dosing Units 51 8. 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.
Digital Dosing Units 52 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). 18. Mount the profile clamp. 19. Mount the screw at th e profile clamp and tighten.
Digital Dosing Units 53 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 bef ore starting to work at the unit or controller.
Digital Dosing Units 54 Appendix A: Troubleshooting During setup and use of the Digital Dosing Additive Feeder, personnel may experience difficulties. Some of the problems enc ountered may be resolved using the following techniques. A.1 General T roubleshooting - Unit Will Not Operate • Check all connections and process wiring.
Digital Dosing Units 55 ERROR CODES Code Definition Possible Reason/Solution A001 Strap “safety switch” is missing. Manufacturer Service. A002 The nominal current of the dosing motor (=100%, see name plate) is being exceeded for more than 2 seconds by 30% or for a maximum of 0.
Digital Dosing Units 56 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 select ion column.
Digital Dosing Units 57 Extrusion For extrusion applications co mpute the dosing disc speed using the following formula. Recipe limitations are listed in the table following the recipe. Disc RPM ( Additive - %) x (Total Extruder Throughput - lb / hr) 13.
Digital Dosing Units 58 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.
Digital Dosing Units 59 Frequency [Hz] = Input cu rrent [mA] x 10000 [Hz] 20 [mA] Note the data: Min. input frequency = __________ Hz Max. input frequency = __________ Hz Calculate the span factor usi.
Digital Dosing Units 60 • Throughput: 8000 g/min • Totalizer displayed in lbs • Extrusion mode Raw material probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Additive probe . . . . . . . . . . . . . . . . .
Digital Dosing Units 61 Optional blending (mixing) unit insta lled . . . . . . . . . . . . . . . . . . . . . .8 ___ Totalizer displayed in lb (kg defaul t) . . . . . . . . . . . . . . . . . . . . . . . . . 16 ___ Shot weight (1 kg-6.5 Kg) …………….
Digital Dosing Units 62 Additive probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Blending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 __ Totalizer displayed in lb. .
63 Appendix C: Dosing factors, equipment drawings and part number s Disc Dosing Factor Table 1: Disc Guide Disc Disc Nomenclature Used in the Controller Minimum/ Maximum Disc Revolution Weight Per Disc Revolution (35 lbs/cu. ft.) Min. Throughput with 100% Continuous Running (35 lbs.
64 DD30 051818 Default Calibration # 13.5 grams/rev 051818 # of Holes Diameter Disc Thickness 0.2 Rev./min (6.4 RPM) 0.5 Rev./min (11.5 RPM) 1.0 Rev./min (35.5 RPM) 13.42 g/Rev. 0.75 g/Hole 0.35 lb/hr 0.16 kg/hr 0.85 lb/hr 0.39 kg/hr 1.76 lb/hr 0.80 kg/hr 11.
65 DT30 204010F Default Calibration # 150 grams/re v 204010 # of Holes Diameter Disc Thickness 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 4.00 lb/hr 1.80 kg/hr 10.00 lb/hr 4.53 kg/hr 20.00 lb/hr 9.
66 Specification Sheet DIGITAL DOSING UNIT TE CHNICAL PARAMETERS Disc Dosing Factor Table 2 Maximum Number of Feed Stations One (1) for Granule Processing Maximum Product Temperature 80 o C (or 176 o F) Weight (Approximately) 20 kg (44 pounds) Connected Loads 0.
67 Starter Calibration Parameters DD Discs Disc Calibration Number DD 30-030673 1.75 Parameters Default Units Description 1 Additive % Percent Using the arrow keys, set additive ratio. 2 Shot size of the current mold Grams/pounds Using the arrow keys, set the shot size of the current capacit y in grams/min or po unds/min.
68 Digital Dosing unit parameter setup 1-4 for extrusion proportional Parameters Default Units Description 1 Additive % Percent Using the arrow keys, set additive ratio.
69 10 5.56 10 5.56 Ext = Span factor (sf) calcul ated using: sf=1000/rpm@10vdc sf = 1000/rpm @20ma 13 Ext Inj Ext Inj 0 0 0 0 Communication addr ess used with Euromap 17 (use 1 ins tead of 0) 14 Ext I.
.
71 Station 1 Digital Dosing Unit SIDE VIEW TOP VIEW.
72 Station 2 Digital Dosing Unit SIDE VIEW TOP VIEW.
73 General Wiring Diagram for Bauer Motor.
74.
75 Dosing Unit Electrical Schematic Chart for Bauer (blue) motors only Drawing No. Description of Drawing Voltage CT102020 C150 CONTROLLER INJECTION 110 CT102021 C150 CONTROLLER EXT-S SIMPLE EXTRUSION.
76 Appendix D: Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers CT 100562 49 chambers CT 21710 25 chambers CT 21711 18 chambers CT 2057 Dosing disc, wear-resistant 40 chambers .
77 Control System Order Numbers Fuse Size Voltage Amps Type Part Number F1 5X20 250 V 5 A Metric A0571836 F2 1/4X1 1/4-250 V 4 A Time Delay CT99107 F3 5X20 250 V 0.5 A Time Delay CT96398 F4 5X20 250 V 0.5 A Metric CT102258 F5 5X20 250 V 0.5 A Metric CT102259 F7 5X20 250 V 0.
78 - Notes-.
73 Technical Assistance Part s Dep artment Call toll-free 7am–5pm CST: [ 800 ] 783-7835 The ACS Customer Service Group will prov ide your com pany with genui ne OEM quality parts manufactured to engineerin g design specificatio ns, which will maximize your equipment’s performance and efficiency.
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