SDD Digital Dosing Units Part Number: 882.00276.00 Bulletin Number: BF3-600 Effective: 12/01/05 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.
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Table of Contents SECTION 1: INTRODUCTION …………….……………………….………...3 1.1 Controller. ..............................................................................................................4 1.2 Keys and Symbols..................................................................................................6 SECTION 2: QUICK START-UP……………………………………………...8 SECTION 3: INITIAL INSTALLATION AND OPERATION….………….……………………………………………………..11 3.1 3.2 3.3 3.4 3.5 3.6 Initial Installation ...........................
Section 1: Introduction This User’s Manual is intended for use with the Digital Dosing 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. It can be used on both extrusion and injection molding machines.
Q U I C K S T A R T P A G E S Figure 2.
1.1 Controller The Digital Dosing additive feeder consists of a controller, dosing motor, and feeder(s). The controller is used to • Enter, recall, and run recipes • To run, monitor, and stop the dosing process • To calibrate • To troubleshoot problems via error codes • To configure the unit to the desired process. A touch keypad (see Figure 3) is used to enter or change data. • The Control system is switched on by means of the On/Off switch (switch set in position “1").
Q U I C K 1.2 Keys and Symbols 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 increasing/decreasing of the set value in larger increments.
Symbols 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 Lights when an alarm occurs.
Section 2: Quick Start-up 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. If any damage is noted, contact manufacturer for replacement or service. 4.
3. Press Input to display #2, “Shot size of current mold”. Using arrow keys, set the total shot size (parts and runners) of the current mold capacity in grams. 4. Press Input to display #3, “Screw recovery time”. Using arrow keys, set the screw recovery time (in seconds). For Extrusion Constant operation, skip this step! 5. Press Input to display #4, “Calibration weight for additive”. Enter ’0’ and proceed to calibration mode below for calibration of additive material. Recipe Setup For Extrusion: 1.
6. Repeat step #19 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 Q U I C K of all calibration weights entered. 7. After all five samples have been completed; press “calibration” once more and this will save the calibration weight of the material to the recipe.
Section 3: Initial Installation And Operation 3.1 Initial Installation Hopper Piece Processing Machine Direction of Material Flow Figure 4. Digital Dosing Unit Assembly 1. The Digital Dosing additive feeder is not 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.
be exposed to extreme heat (maximum temperature 45°C or 115°F) or excessive moisture. 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 Figure 5, electrical diagram. J12-3 J12-2 Relay contact Injection molding Machine Digital Dosing controller (Electrical diagram of connections) Figure 5.
NOTE: Zero input corresponds to zero screw speed and no additive dosing. Maximum input corresponds to maximum screw speed. NOTE: If a 0-10kHz frequency input is used, it must be a square wave with an amplitude of 12VDC. The shape of the signal is important, especially above 7,000Hz. J12-4 _ J12-3 + 0-10vdc or 0-20ma Extruder output Digital Dosing controller (diagram of frequency inputs) Figure 6. Frequency Inputs 5. Make sure the unit is turned OFF before plugging it in.
• Recipe parameters are different for Injection Molding, Extrusion-Constant, and Extrusion-Proportional operation. See each individual section for details. • The calibration method is the same for all processes. • Once the unit is online, the user may want to save recipes for later recall (10 maximum). • This section will show how to calibrate the unit, bring the unit on line, enter a recipe, and store and recall recipes. 3.
• 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. The double arrow key allows the user to ramp up or down by larger increments.) Step 2: • Press Input • 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 again. come up on the display. • Enter the shot weight using the arrow keys.
this value during operation. The range of values that can be entered in this field is 00.50 to 99.99 seconds. Step 4: or • Press Input • The symbols “g” or “lb”and • After “4” quickly flashes on the screen, a number in the format xxxx.x will come a fourth time. flash. up on the display. • Enter the material calibration weight using the arrow keys. • If the calibration weight is unknown, reference Section 5 of this manual. Complete the calibration procedure (section 3.
• After “5” flashes on the display, a number in the format xxx.xx will come up on the display. • 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.
1. Pressing again will first display the number “18” and then will display the total throughput in kilograms (totalizer). 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 ( ) continuously for five seconds until the display is reset to “00.00.” 3.
light on the controller during screw recovery. The disc symbol will light when the Digital Dosing unit is dosing material. • The totalizer will increase after each cycle by the amount of material dosed. • 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 current recipe is the average of the last five shots measured from the molding machine.
• Press • The • After “1” flashes on the screen, a number in the format xxx.xx will come up on once. symbol will flash. the display. • 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. The double arrow key allows the user to ramp up or down at a faster rate. Step 2: or • Press again.
• Press • The machine displays a flashing a third time. , “g” or “lb” and a number “4”flashes on the display (because this is Extrusion Constant, step 3 is skipped). • After the “4” flashes on the display, a number in the format xxxx.x will come up. • Enter the calibration weight. If the calibration weight is unknown, enter “00.00” and complete the calibration procedure (section 3.6) to obtain the correct value.
Step 5: 6. Press again. 7. The number “18” will be displayed before the total throughput in kg is displayed. 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. 2. If desired, clear the totalizer by pressing continuously for 5 seconds until the display is reset to “00.00.” 3. Place the Digital Dosing unit into operation by pressing .
NOTE: See Appendix A, Troubleshooting, for information on problems or errors encountered and their resolution. 3.
Step 2: or • Press • The machine displays a flashing “g” or “lb”, a flashing “min” and • After “2” flashes quickly on the display, a number in the format xxx.xx will again. . 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 001.0 to 6500 grams per minute (00.01 to 14.30 lb/m).
Step 4: or 1. Press a fourth time. 2. The machine displays a flashing and “g”. 3. 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 or pounds. If the calibration weight is unknown, enter “00.00” and complete the calibration procedure (section 3.6) to obtain the correct value. Upon completion of the calibration procedure, the calibration weight will automatically be updated into the recipe.
2. Place the Digital Dosing unit into operation by pressing the Run key ( ). 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 will light on the controller when the extruder starts. The disc symbol will light when the Digital Dosing is dosing material 4.
Determining the Calibration Weight Step 1: • To start the calibration process, press the calibration key. Step 2: • Once the sample container is in position, press • The disc will rotate 1/4 revolution and dispense material into the sample . container. After the disc stops, the screen will remain blank. • This sample should be returned to the material hopper without weighing. This sample is used only to ensure that all disc pockets are completely filled.
• 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: • Enter the weight, in grams using the Arrow Keys • Empty and replace weighing container in calibration box (or under material outlet tube) Step 5: • Repeat steps 3 and 4 four (4) more times. • Notice that the displayed calibration weight may change after each sample weight is entered.
• Pressing the stop button will stop proportioning and not accept the calibration weight. • 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.
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 at any time will exit the Recipe Storage/Recall mode. Recipe Storage To store the current recipe: Step 1: • ). A two-digit number (01 through 10) will Press the Recipe Storage/Recall key ( appear on the screen.
• Press and hold the button • The recipe is now stored under the selected ID number. until the totalizer display returns to the screen. Recipe Recall Step 1: or • Press the stop button to stop any current applications. • Press the Storage/Recall key ( • A two-digit recipe ID number will appear on screen. • Use the Arrow Keys Step 2: ) once. Step 3: to select the desired recipe number.
• Press and hold • The recipe is now active and can be run or edited. until the totalizer appears on the screen. NOTE: The recalled recipe now becomes the active recipe. 4.2 Clearing The Totalizer • The totalizer displays the total amount of additive dosed since the last time the totalizer was cleared. • The totalizer can be cleared by pressing Stop continuously for 5 seconds until the display is reset to “00.00.” The totalizer can be configured to read throughput in grams or pounds.
Alarms Several alarm options are available for the Digital Dosing feeder. The standard unit comes with a flashing alarm symbol 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 Probes To adjust the level probes: 1. Turn the controller ON. 2. Fill the dosing station until the level sensor is one-third covered. 3.
Mixer An optional mixer is available that can be mounted under the Digital Dosing unit. The mixer is used to help distribute fine powders and granules. During the injection molding process, the mixer only runs during screw recovery (when the Digital Dosing unit is dosing additives). During extrusion processes, the mixer operates continuously when the extruder is operating and the Digital Dosing unit is in run mode.
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. Every 3 months: Check scraper in dosing station DD/DT. Check all electrical and mechanical connections for Every 6 months: tight fit. Annually: Check dosing disc in dosing station DD/DT. Each time after material Is changed: Clean the dosing station. Check adjustment of the level probes (optional). Check scraper.
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 scraper (A). Installing the scraper 1. Place the new scraper in the dosing unit housing. 2. Ensure that the scraper is positioned correctly. 3. Screw the scraper 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.
5. Remove the dosing hopper from the dosing unit. 6. Dismantle the dosing unit and remove the scraper (D). 7. Loosen the two hexagon socket screws (B, M6 x 30) on the top 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. 9. Lift the dosing disc (A) from the dosing unit housing (B) by this screw. 10. Clean the scraper using a cotton cloth. 11. Clean the dosing hopper and the dosing disc in soapy water. 12.
5.4 Changing the Dosing Disc in the Digital Dosing Dosing Station Removing the Dosing Disc 1. Empty the dosing station. 2. Switch the control unit off by means of the on/off switch. 3. Dismantle the dosing unit and remove the scraper. 4. Loosen the two hexagon socket screws (M6 x 30) on the top side of the dosing disc. 5. Loosen the center hexagon socket screw (M6 x 12) and replace by a M6 x 60 screw. 6. Lift the dosing disc from the dosing unit housing by this screw. Installing the Dosing Disc 1.
Installing Different Types of Dosing Discs 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 (* = bulk density 550g/l, ** = bulk density 700g/l). . 2. Execute “calibration” to determine the final calibration value 5.5 Removing/Replacing the Scraper in the DT Dosing Station 1.
9. 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. Empty the dosing station. 2. Switch the control unit off by means of the on/off switch. 3. Disconnect from mains voltage. 4. Open the profile clamp (C) of the dosing container. 5. Remove the profile clamp (C). 6. Remove the dosing container (B) along with the dosing hopper (A). 7.
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 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.
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 on page 61 for fuse part numbers.
Appendix 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 • Check all connections and process wiring. Note that the process machine input MUST be wired to a DRY contact for Injection Molding (Section 2.8.1) and Extruder Constant Applications (Section 2.8.2).
ERROR CODES Code A001 A002 Definition Strap “safety switch” is missing. 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 0.5 seconds by 80%. A003 The nominal current of the dosing motor (=100%, see name plate) is being exceeded for more than one minute. A004 Excess temperature.
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. The total is the Software Setup Factor. A.
Disc RPM = ( Additive - %) x (Total Extruder Throughput - lb / hr) 13.22 x (Disc Calibration Weight - g) Recipe Limitations Extrusion Motor Assembly Speed (RPM) Maximum Speed (RPM) 12 38 12.5 40.
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: • Frequency signal (must be 12VDC square wave) • 0-20mA current signal • 0-10VDC signal Determine 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.
If a current signal is available (0 - 20 mA) calculate the frequency output of the extruder for the lower / upper working area using the formula: Frequency [Hz] = Input current [mA] x 10000 [Hz] 20 [mA] Note the data: Min. input frequency = __________ Hz Max.
Alarm output is switched in case of power failure . . . . . . . . . . . 512 ___ Extrusion mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024 ___ Printer available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16348 ____ Configuration value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Totalizer displayed in lb (kg default) . . . . . . . . . . . . . . . . . . . . . . . . . 16 ___ Shotweight up to 6.5 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 or Shotweight 6.5 to 65 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ___ (NOTE:The shotweight selections above determine placement of the decimal point on the display) External run/stop signal controls dosing . . . . . . . . . . . . . . . . . . . . . .
Basic Parameter Settings Digital Dosing Units 51
Digital Dosing Units 52
Digital Dosing Units 53
# of Holes Diameter Disc Thickness 051040 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4 Rev./min (6.4 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) Minimum/ Maximum Disc Revolution 0.11 g/Hole 4.24 g/Rev. 1.63 kg/hr 6.33 lb/hr 2.87 kg/hr 0.27 lb/hr 0.12 kg/hr 3.59 lb/hr 0.05 kg/hr 0.11 lb/hr 3.25 kg/hr 0.09 kg/hr 1.05 kg/hr 0.045 kg/hr 7.16 lb/hr 2.32 lb/hr 0.10 lb/hr 0.19 lb/hr 0.59 kg/hr 0.02 kg/hr 0.
# of Holes Diameter Disc Thickness 101820 # of Holes Diameter Disc Thickness 051818 # of Holes Diameter Disc Thickness 051725 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4 Rev./min (6.4 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4 Rev. /min (6.4 RPM) 1.40 g/Hole 28.00 g/Rev. 10.
# of Holes Diameter Disc Thickness 204010 # of Holes Diameter Disc Thickness 203012 # of Holes Diameter Disc Thickness P102025 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 15.12 g/Hole 151.15 g/Rev. 7.
# of Holes Diameter Disc Thickness P250940 # of Holes Diameter Disc Thickness P050940 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 0.2 Rev./min 6.4Rev./min (6.4 RPM) 0.20 g/Hole 7.82 g/Rev. 0.39 g/Hole 15.64 g/Rev. 3.00 kg/hr 10.55 lb/hr 4.78 kg/hr 36.70 lb/hr 16.65 kg/hr 0.46 lb/hr 0.21 kg/hr 1.00 lb/hr 0.47 kg/hr 13.2 lb/hr 0.093 kg/hr 0.
Maximum Number of Feed Stations Maximum Product Temperature Weight (Approximately) Connected Loads Operating Voltage Special Voltage Option 58 One (1) for Granule Processing 80oC (or 176 oF) 20 kg (44 pounds) 0.
Parameter 14 13 Inj 0 0 0 Ext 0 Inj 5.56 10 Ext Inj 50 Ext 50 Ext 11 12 Inj 0 16 1040 14103 12 Inj 0.5 25200 6 Ext 65000 2 10 9 8 7 RPM Bison - Black motor 38 4387 Digital Dosing unit parameter setup 7-14 Ext 0 0 Ext 10 Ext 50 Ext 1040 Ext 11739 6.4 1 0.7 6600 11.5 35.5 59 Inj 0 0 Inj 5.
Station 1 Digital Dosing Unit SIDE VIEW TOP VIEW 61
Station 2 Digital Dosing Unit SIDE VIEW TOP VIEW 62
Dosing Unit Electrical Schematic Chart Drawing No.
Appendix D: Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers ID 100562 49 chambers ID 21710 25 chambers ID 21711 18 chambers ID 2057 Dosing disc, wear-resistant 40 chambers ID 28214 25 chambers ID 27141 18 chambers ID 27142 Shear for DD style unit 18, 25, 40 pocket disc ID 21392 72 pocket disc ID 100875 Shears Standard ID 21392 72 chamber only ID100875 Control System Order Numbers Fuse F1 / F7, 5 AT 84773 F2, 4 AF 84770 F3, 0,5 AF 83670 F4 / F5, 2 AT 9981
-Notes- 65
Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005 The ACS Customer Service Group will provide your company with 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.
