Home

Sterling 882.01749.00 Welder User Manual

1. 9 A250 CODO dti iua s 10 2 2 E Du 11 HD ACHTING Mem 11 MOUNUN O C H 11 Feeder Configuration Injection 20120000001500000005000 enne 12 Recipe Setup Injection 2 2 1 0000000 000000000000 15 Feeder Configuration Simple extrusion enne 17 Feeder Configuration Extrusion follower 222 4 2 6 60 0120 00 000050000 22 CHAPTER 3 INSTALLATION AND OPERATION 31 dee etre 31 Ini ODeratioflo vidt sni acies iia a ada edat cus 34 9 9 WAC CID SS TET 35 ee 41 3 5 lallus SCIOOGLIS ust MEME 44 Opina 63 Level SWITCNES D 63 Communication Protocol Irit rfae6S ein e eun 65 OP TONALAGdiUve HOPPETS iei tede tese 65 Virgin Material Supply 67 CHAPTER 4 68 4 1 Preventative Maintenance Intervals 68 4 2 Removing the Shear Plate DD dosing
2. 70 Removing 5 LL 70 MS TAMING WIG SING UE 70 4 3 Removing the DD Disc and Cleaning the Dosing Module 71 Dismantling the Dosing ModUle e Ree Eee eite Casa tectis 71 Installing Dosmng Mod l 3 o oc erae emu i tee mtb evt Made 72 Installing Different Types of DOSING 5 72 44 Removing Replacing the Wiper in the DT Dosing Station 74 4 5 Removing the DT Disc and cleaning dosing station 75 4 6 Removing Replacing the DT Disc amp Cleaning the Dosing Station 77 4 7 Removing the DP Disc and Cleaning the Dosing Station 78 4 8 Exchangeable Dosing 79 4 9 PAS T DT 80 882 01749 00 iv APPENDIX A BASIC PARAMETER SETTINGS 84 MECU MOIN pee ern ae eer enn tenner T 84 84 APPENDIX DISC SIZING GUIDES 85 APPENDIX 8 lt 87 APPENDIX D SPARE PARTS LIST
3. Lael Desi Ae qoas epum Bona HOPPER 8 CARE Pe er Cee Ej mer 7 OPA CARME LO BL a ARES TER pA AH wet AMT Me CeR T USED TC HOPPIN STAINLESS STEEL SUPPLY HOPPERS 208mm FLANGE 8 197 DIA ALL STAINLESS STEEL SUPPLY HOPPERS INCLUDE FINGER GUARD AND RING CLAMP DUALS DIA _ SIGHT GLASSES CT29 2464 ADAPTER HOPPER ASSY 2080 RING CLAMP INCLUDED ADAPTER HOPPER ASSY 208D 253D RING CLAMP INCLUDED AOS9454IK ADAPTER HOPPER ASSY 253D 5RC LOADER 00 4 4L SUPPLY HOPPER UNIT REQUIRES 2 ROLL PIBS CTAAOZ7 BF 4 4L SUPPLY HOPPER DT STAINLESS STEEL HOPPERS ARE MOST OFTEN USED MOUNT A LOADER AUTOMATICALLY KEEPING THE SUPPLY HOPPER FULL OPPOSED A OPTIOM SKSHTGLASSES ARE THE EASIEST WAT CHECK FOR PROPER PERFORMANCE 206mm FLANGE B 19 DIA WALT DIA CLASSES 77 832 01782 00 8 8L SUPPLY HOPPER UNIT REQUIRES 2 ROLE PINS CTAO B8320 981 00 B BL SUPPLY HOPPER DT 882 01749 00 CTIO2DO4 4 41 SUPPLY HOPPER DD DP DP LIMIT REQUIRES 2 PIRG CTAAQ27 CTIO2112 4 4L SUPPLY HOPPER DT 66 of 93
4. 91 APPENDIX E TECHNICAL ASSISTANCE 92 FANS CD AMINO BERT 92 Service Depan 92 SACS 92 Contract DepaFtrnilil 92 882 01749 00 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation These instructions are intended to supplement standar
5. 11 wed ak 11 147 3 1717777 TETTE Wi BAR TA Tm Ce Chia CAUBRARCM CALA Te err 1 GRE MA FERA T BORDAS AND LT CH Fath NGC CON UE 1o DENM 882 01749 00 73 of 93 4 4 Removing Replacing the Wiper in the DT Dosing Station 1 Switch the control unit with the On Off switch 2 Disconnect the power supply 3 Empty the dosing station 4 Open the toggle latches on the dosing motor Remove the dosing unit from the A dosing motor 6 Open the profile clamp C of the dosing container 7 Remove the profile clamp C Remove the dosing module and 9 Loosen 3 plastic screws DT 30 the wiper 10 Remove the wiper and holding plate 11 Install the new wiper along with the holding plate 12 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 13 Install the dosing hopper on the dosing housing ensuring the guide pin is in place and locate the shelf above the module discharge hole 14 Install and ti
6. Calibration weight is determined from chart 5 1 and is dependant on the disc installed in the feeder This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for recipe validation and feed rate calculation If samples are not weighed as described in the next section this value is used during operation The weight can be entered in ounces or grams The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value initially displayed is the weight which would result in a motor speed of 25 The valid range of values would then be to 5 times this initial value Additive Sample weighing Weighing samples of additive provides for more precise control of feed rate Up to 5 samples can be weighed All weights entered are averaged to arrive at a value to be used during operation The weighing process may be skipped altogether in which case the calibration weight is used for calculations of feed rate See the section Weight Calibration at the end of this section 882 01749 00 37 of 93 Simple Extrusion Recipe In order to calculate the correct motor speed required to feed the desired amount of additive the following data must be entered 4 Additive 5 Throughput 6 Calibration weight In addition for the greatest accuracy
7. EE a 832 00040 00 ACRYLIC HOPPER 4 4 LITER ACRYLIC ONLY ae te 832 00041 00 ACRYLIC HOPPER 8 8 LITER ACRYLIC ONLY 892 01490 00 KIT HANDLE DD DT DP SUPPLY HOPPER CT92228 V CLAMP DD DT TP HOPPER TO DISK HOUSING 6 16613 HOOKFORTOGGLECLAMP 8 CT34299 IEA DOSING MOTOR ASSEMBLY 38RPM 9 0241 IEA DOSING MOTOR ASSEMBLY 115 RPM 892 02095 00 DOSING MOTOR ASSEMBLY 3 RPM 882 01749 00 83 of 93 Appendix A Basic Parameter Settings A 2 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 Recipe Limitations for Injection Molding Motor Speed rpm Max et rpm Min Speed rpm Extrusion Simple 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 Speed rpm Maximum Max Speed rpm Min Speed rpm 2190 882 01749 00 84 of 93 DD30 030672 Default calibration 1 50 g rev DD30 050660 Default Calibrati
8. Injury could result if fingers are pinched between the rotating disc 882 01749 00 68 of 93 DD Dosing Module Pellets E PART SP RON j 1047 SC ALMRANON BOX COO CANAAN 16112007 DOO MACH f IATDCOAT OTE CALERA 80x MOGs DESTACO CLAMP 116444 COVER BOX E COVER CAL Mor CO 16721392 turae COO 30 COASA DOTIO 16121710 0090 40 POCKET 0107704 DOUBLE oW 000 830 27 15100029 116 SCREW PAN PHELIPS Maxi 2 SOCKET M x T je1 00023 145 SCREW SOCKET MAS 40 IP 177 Ww SOCK x36 cms Isceew max io DD DISK AND HOUSING FOR DOSING PELLET ADDITIVES a m n aed OR KHED Ba LEVELS OFF MATERIAL TRAPPED iN POCKETS AS 19 157100023 134 PEW ET 14 THE DISE ROTATES IOS WASHER LOCE M C125023 WEAR RELSTANT 1 gt 51200542 OC DOS 72 POCEET THIS CFE 6 HARDER AND MOST PESISTANT TO 16121711 DOJOQ 25 WEAR CUTTOMER 5 FREQUENTLY PEPLACING C1223087 Gc ODID 18 OR SHARPIMING CHIVES USE ING PART AS A p DEAE 00 79 1110007 05 72 REPLACEMENT 22 0164244 IMAT CAL fox o W CLAMP SECURES THE HOPPER TO THE FLQUWES SPECIAL 21 065 AR
9. 5700 change the value press the value on the screen to activate the keyboard Key in the correct value and press the key Motor Color RPM Encoder Pulses 882 01749 00 54 of 93 Bodine Black amp silver Bodine Black amp silver Bodine Black amp silver Bodine Black amp silver Motor and alarm utilty selection The Speed Alarm settings screen can be activated by pressing the Speed Alarm button The Drive Tuning screen be activated by pressing the Tune Drive button See the following sections for these screens 882 01749 00 55 of 93 Drive Tuning 1 2 11 5 The drive tuning screen is provided as an aid to tuning the drive to match the motor and load of the A250 feeder Pressing the Min button will send the minimum drive signal to the controller Pressing Max button will send the maximum drive signal to the controller Pressing the Stop button or leaving this screen will terminate any signal sent to the controller The numbers on the left are the target min max values The numbers on the right are the actual speed values A small screwdriver preferably non metallic is needed to tune the drive Tune the drive as follows Speed Alarm peed Deviation 5 Alarm Delay 2 Sec ALARM SI The reaction to deviations from the commanded speed are controlled via this screen Speed deviation specifies the w
10. 64 Measure 6A Additive Sensor 6B Virgin Sensor 6C Passwords 6D Digital Monitor 6E Analog I O Monitor Simple Extrusion Press Screen Title Function 60 Press Type 61 Max Motor Speed 62 Encoder Pulses Tune amp Speed 76 Default Add 63 Measure Default Thruput 65 Meas 6A Additive Sensor 6B Virgin Sensor 6C Passwords 6D Digital Monitor 6E Analog I O Monitor Extrusion Follower Press Screen Title Function 60 Press Type 882 01749 00 Prev Screen N A Press Type Max Motor Speed Encoder Pulses Tune amp Speed alarm Default Add Measure Default Shot Measure Additive Sensor Virgin Sensor Passwords Digital Monitor Prev Screen N A Press Type Max Motor Speed Encoder Pulses Tune amp Speed alarm Default Add Measure Default Thruput Meas Additive Sensor Virgin Sensor Passwords Digital Monitor Prev Screen N A Next Screen Max Motor Speed Encoder Pulses Tune amp Speed alarm Default Add Measure Default Shot Measure Additive Sensor Virgin Sensor Passwords Digital I O Monitor Analog I O Monitor Setup Menu Next Screen Max Motor Speed Encoder Pulses Tune amp Speed alarm Default Add Measure Default Shot Measure Additive Sensor Virgin Sensor Passwords Digital I O Monitor Analog I O Monitor Setup Menu Next Screen Max Motor Speed 51 of 93 61 Max Motor Speed 62 Encoder Pulses Tune amp Speed 76 alarm Default Add 63 Measu
11. See section for details Prev 11 5 RPh SIGALAL s a v 624 5 Enter Read Maximum press signal See section for details RPM 44 8 Maximum Motor speed Enter motor speed ENCODER 42345 PULSES Prev Done Encoder pulses per disk revolution See table Motor Color Encoder Pulses Bodine Bodine Bodine Bodine 882 01749 00 Black amp silver Black amp silver Black amp silver Black amp silver 23 of 93 la fault 882 01749 00 Motor and alarm utilty selection Drive tuning Perform drive tuning See section for details 1 2 11 5 Speed Alarm setup Select alarm option Alarm amp stop alarm only or no alarm peed Deviation 5 Alarm Delay 2 Sec ALARM SI ene DEFAULT ADDITIVE MEASURE nooo GR or OZ Select the measure commonly used at your facility DEFAULT THROUGH PUT MEASURE Extrusion Press GR KG OZ LB Select the measure commonly used at your facility 24 of 93 AUDIT VE WATER LAL SENSOR SENSOR Additive sensor Select the no sensor alarm only or alarm amp stop WATER LAL SENSOR SENSOR Virgin material sensor Select the no sensor alarm only or alarm amp stop Recipe Setup for Simple Extrusion In order to calculate th
12. Virgin Material Supply Hoppers Various virgin material supply hopper options are available if your existing hopper will not work properly with the Digital Dosing feeder Contact the Sales Department at 810 720 7300 for more information SINGLE COMPONENT ALUMINUM BASE BECAUSE THE FEEDER CAN BE MOUNTED DIRECTLY CHER THE INLET A POWDER FEEDER DP BE MOUNTED THIS PEDET AL COH V AETA Titer Steer ATHAFTEB BARAT D LI Re CTIDIERZ STANDARD 27 CAST ALUMINUM BASE WITHOUT DRAIN ES BAATERLAL CAST EPOXY COATED INSIDE AND OUT 882 01749 00 67 of 93 Chapter 4 Maintenance 4 1 Preventative Maintenance Intervals Check warning signs on equipment for good legibility and completeness Check function of the On Off Switch Check shear plate and mounting hardware in DD dosing Station Every 3 Check wiper and mounting hardware dosing station months Check that all electrical and mechanical connections are Every 6 ti ght months Check adjustment of the level probes optional Annually Check dosing disc in dosing station DD and DT Clean the dosing station Each time after materia Check shear plate or wiper Is changed Check dosing disc CAUTION Always disconnect power and remove the dosing module from the motor assembly before taking the dosing module apart
13. 49 771bs hr 63 3 Ibs hr Default CT66707 1 0 RPM 4 36 Ibs hr 5 55 Ibs hr 165 81 Ibs hr 211 1 Ibs hr 33 00 ED 3 RPM 1 14 kg hr 1 42 kg hr 17 11 kg hr 21 3 kg hr 20 mm thick 0 2 RPM 2 51 Ibs hr 3 13 Ibs hr 105 66 Ibs hr 131 9 Ibs hr Default 12 holes 0 5 RPM 79 8g hole 9 8 g hole 6 28 Ibs hr 7 80 1 5 143 28 Ibs hr 178 0 Ibs hr 95 00 g rev CT23060 1 0 RPM 12 50 Ibs hr 15 65 Ibs hr 477 99 lbs hr 596 8 Ibs hr 204010F 3 RPM 1 80 kg hr 2 25 kg hr 27 22 kg hr 34 0 kg hr 24 40 mm dia 8 4 RPM 151 1 g rev 188 7 g rev 1 80 kg hr 2 25 kg hr 76 20 kg hr 95 2 kg hr a 10 pockets 0 5 RPM 15 1 g hole 18 8 g hole 10 00 lbs hr 12 431bs hr 227 74 Ibs hr_ 283 5 Ibs hr Default ES 11 5 RPM 4 53 kg hr 5 64 kg hr 103 28 kg hr 129 0 kg hr calibration 1 0 RPM 20 00 Ibs hr 25 00 Ibs hr 754 65 lbs hr 948 3 Ibs hr 150 00 g rev 38 RPM 342 30 kg hr KT 3 RPM 0 093 kg hr 0 115 kg hr 1 40 kg hr 1 76 kg hr 9 mm diameter 84 7 8 g rev 9 7 g rev 0 093 kg hr 0 115 kg hr kg hr 4 91 kg hr Default 20 pockets 0 5 RPM 02 ghole 0 46 Ib hr 0 60 Ib hr 10 79 Ibs hr 13 57 Ibs hr calibration 100864 11 5 RPM 0 21 kg hr 0 27 kg hr 4 90 kg hr 6 15 kg hr 7 80 g rev 1 0 RPM 1 00 Ib hr 1 30 Ibs hr 39 28 Ibs hr 49 08 Ibs hr 38 RPM 0 47 kg hr 0 58 kg hr 17 82 kg hr 22 26 kg hr DP30 050940 P050940 0 2 RPM 0 41 Ib hr 0 51 Ib hr 6 19 Ibs hr 7 73 Ibs hr 3 0 187 kg hr 0 23 kg hr 2 81 kg hr 3 51 kg hr 9
14. ENTER WEIGHT 12 34 GR Enter the sample weight obtained from the previous cycle of the feeder The unit of measure will be the same as used for the calibration weight Pressing the Enter symbol on the screen keypad displays Screen 7 Screen 7 TO CONTINUE 12 34 GF 1 OF 5 SAMPLES The screen displays the running average of sample weights as well as the number of samples taken Pressing Next will repeat the process at Screen 4 if less than 5 samples have been taken otherwise Screen 8 will be displayed 882 01749 00 43 of 93 Screen 8 RAWOVE TRAY REPLACE SAMPLING COMER PRESS MEST vex The tray should be removed from the calibration chamber The access cover should be replaced closed Weight Calibration 1s complete Note that at any time in the process the Menu button may be pressed to abort the weight calibration process Any sample weights if any are used to calculate the average weight If no sample weights are entered the calibration weight is used for calculations Using less than 5 samples may affect feeder accuracy 3 5 Status screens Status Screens The status screens reflect the state of the feeder during operation The status screens are accessed by pressing the Status button on the main menu Prerequisites Before the status screens can be displayed the current recipe must be valid amp complete If the current recipe is not valid an advi
15. Setup passwords By default these are set to 0 which disables the password requirement Setting the password to a non zero value activates password protection To set change the Operator password press the value next to Operator and enter the new password using the screen keyboard To change the password duration press the duration value amp enter the new duration using the screen keyboard The Setup password and duration are entered in the same way Refer to Table 4 2 for password requirements based on which passwords are enabled 882 01749 00 61 of 93 Table 4 2 Password requirements No Passwords Operator Only Set Active Recipe Functions X O System Start Stop X O Manual Jog Run X O System Setup X O X None O Operator S Setup Digital Monitor 15 Setup Only Active Operator Setup Active This screen monitors the PLC inputs and outputs When an input or output is on the indicator is displayed white on black When an input or output is off the indicator is displayed as black on white If using the Modbus communications option the node station number is set here Valid node numbers are 0 32 882 01749 00 62 of 93 Analog Encoder Monitor ENC CH 12345 OUT cum Jog This screen monitors analog input amp output as well as raw encoder value input Additionally the encode
16. T Ur QUEDA CREW Smm METERING DEEPER GROVES PROVIDE MOSE PER REVORUTION TA iii NATI Tren METER QUICK FELEASE LATCH ALLOWS FOR EASY REMOVAL AND OF THE AND HOPG ALLEMBUES 882 01749 00 76 of 93 30 4 6 Removing Replacing the DT Disc amp Cleaning the Dosing Station 1 Switch the control unit Off with the On Off switch 2 Disconnect the power supply 3 Empty the dosing station 4 Open the toggle latches on the dosing motor 5 Remove the dosing unit from the dosing motor 6 Open the profile clamp C of the dosing container 7 Remove the profile clamp C 8 Remove the dosing module and 9 Hold disc and rotate wiper 10 counterclockwise looking at the disc from the top 11 Remove the wiper and traverse holding plate 12 Install the new wiper along with the traverse holding plate 13 Rotate the wiper clockwise while the metering disc in place 14 Install the dosing hopper on the dosing housing ensuring the guide pin 1s 1n place 15 and locate the shelf above the module discharge hole 16 Install and tighten the profile clamp 882 01749 00 77 of 93 4 7 Removing the DP Disc and Cleaning the Dosing Station 10 11 12 13 14 15 16 Turn the control unit Off Disconnect the power suppl
17. calculated motor speed is less than 5 of the rated motor speed The screen will change to orange and flash in this condition Disc Motor Indicator Press Signal Indicator Displayed when the drive motor is running Injection Screw recovery signal Displayed when press signal 15 detected Simple Extrusion Press Run signal Extrusion Follower Analog speed signal 882 01749 00 46 of 93 Totalizer Screen TOTAL ADDITIE 545 OVERSPEED Displays total additive dosed since A Recipe change Modifying the current recipe will not reset the total Or B Totalizer reset The total 15 displayed in KG if recipe additive is measured in grams or kilograms The total is displayed in LB if the recipe additive is measured in ounces or pounds Rese Rese Pressing the reset button resets the total display to zero Throughput Screen ge D sar Displays the calculated throughput Injection Press Throughput is based on recipe data and measured average screw recovery time A running average of the 5 most recent screw recovery times is used Simple extrusion Throughput is based on recipe data Extrusion Follower Throughput is based on recipe data and the current press speed signal Motor Speed Screen 882 01749 00 47 of 93 OTOR SPEED sar Displays the current motor speed when running and the calculated speed
18. desired amount of additive the following data must be entered 5 Additive 6 Shot Size 7 Screw Recovery Time 8 Calibration weight In addition for the greatest accuracy samples of the additive should be weighed and entered Additive The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the shot size is 200 grams and 8 5 grams of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Shot Size screen Shot Size The shot size specifies the total capacity of the mold in use on the press The value can be entered in grams kilograms ounces or pounds The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen 882 01749 00 36 of 93 Screw Recovery Time The screw recovery time is the estimated screw recovery time and 15 used as the initial value for validating the recipe Actual screw recovery times as measured by the presence of the screw recovery signal are used to fine tune the feed rate during operation The estimated time must be at least 1 2 of the actual recovery time If less than 2 the feeder will interpret the recovery signal as a purge cycle Calibration weight Recipe Calibration Weight 12 38 Prev
19. measure Press the upper right corner to select Grams Kilograms Ounces Pounds 882 01749 00 58 of 93 Additive Virgin Material Sensor AUDIT VE VIRGIN MATER LAL WATER LAL SENSOR SENSOR SENSOR SENSOR Prev ens frre one ff ena These screens select whether an additive or virgin material sensor is present and if so what action to take when the sensor detects no material Press the button in the upper right corner to sequence through the following options SENSOR No sensor is present Default ALARM OLY Sensor is present Display alarm screen amp activate alarm output but keep feeder running ALARM AND Sensor is present Display alarm screen activate alarm output and stop feeder operation 882 01749 00 59 of 93 Press Signal Type Extrusion Follower only SIGNAL 0 10 WOLTS Prev J Next one This screen selects the type of analog signal provided by the press to communicate the press speed Press the button in the upper right corner to select from the following 0 10 WOLTS 0 to 10 volts DC Default 0 20 0 to 20 mA milliamps DC 70 mA 0 to 20 mA milliamps DC Minimum Press Signal Extrusion Follower only 125 4 This screen configures minimum speed of press and analog signal associated with that speed Press the top number to enter the minimum speed
20. samples of the additive should be weighed and entered Additive The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the throughput is 200 grams per minute and 8 5 grams of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Throughput screen Throughput 123 m b5E Prev Press throughput specifies the total weight of material through the extruder per minute The value can be entered in grams kilograms ounces or pounds per minute The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen It is important that this value be adjusted whenever the extruder speed changes 882 01749 00 38 of 93 Calibration weight Recipe Calibration Weight 12 38 Prev Calibration weight is determined from chart 5 1 and is dependant on the disc installed in the feeder This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for recipe validation and feed rate calculation If samples are not weighed as described in the next section this value is used during operation The weight can be entered in ounces or grams
21. 01749 00 31 of 93 2 The following applications require a larger feed stand optional 3 or 4 to prevent material bridging o Machines with total throughput over 200 Ibs hr Machines running regrind larger than 5 16 screen size o Processes with a high percentage of regrind gt 30 o Non free flowing virgin material 1 powder o Consult factory for any special requirements 3 Optimum mounting of the Digital Dosing feeder 15 shown in Figure 4 with the additive being dosed in the first few flights of the feed screw 4 The controller should be remote mounted for operator convenience The control unit must not be exposed to temperatures above 45 C 115 F or excessive moisture 5 Electrical connection to process machine Injection Molding Connect the cycle run cable thin gray two conductor cable to a set of dry NO VOLTAGE contacts that CLOSE for the duration of the screw recovery See Figure 5 Relay contact Injection molding Digital Dosing controller Figure 5 Electrical Interface Connection Diagram Injection Molding or Extrusion Constant 882 01749 00 32 of 93 Extrusion Constant Wire the cycle run cable two conductor gray cable to a set of dry NO VOLTAGE contacts that CLOSE when the screw rotates See Figure 5 The connection inside the controller should be on terminal block 10 and PLC input 5 Extrusion Proportional Wire the cycle run cable to the extruder signal
22. 10 Ib hr 0 045 kg hr Continuous Running 0 12 Ib hr 2 32 Ibs hr 2 89 Ibs hr 0 05 kg hr 1 05 kg hr 1 31 kg hr 0 19 lb hr 0 26 lb hr 7 66 Ibs hr 9 63 Ibs hr 0 09 kg hr 0 12 kg hr 3 47 kg hr 4 37 kg hr 0 02 kg hr 0 03 kg hr 0 19 kg hr 0 24 kg hr 0 02 kg hr 0 03 kg hr 0 50 kg hr 0 62 kg hr 0 04 kg hr 0 05 kg hr 0 66 kg hr 0 83 kg hr 0 17 Ib hr 0 08 kg hr 0 22 Ib hr 0 10 kg hr 6 48 Ibs hr 2 04 kg hr 8 54 Ibs hr 3 87 kg hr 0 05 kg hr 0 07 kg hr 0 76 kg hr 0 97 Ibs hr 0 05 kg hr 0 07 kg hr 2 12 kg hr 2 72 kg hr 0 27 Ib hr 0 12 kg hr 0 35 Ib hr 6 33 Ibs hr 8 00 Ibs hr 0 15 kg hr 2 87 kg hr 3 62 kg hr 0 55 Ib hr 0 70 Ib hr 21 19 Ibs hr 277 08 Ibs hr 0 25 kg hr 0 32 kg hr 9 6 kg hr 12 28 kg hr Consult factory 40 pocket disc and 35 5 rpm motor for small pellets and coarse powder only 0 09 kg hr 0 09 kg hr 0 48 Ib hr 1 00 Ib hr 0 44 kg hr 0 35 Ib hr 0 35 Ib hr 0 85 Ib hr 0 39 kg hr 1 76 Ibs hr 0 80 kg hr 0 24 Ib hr 0 11 kg hr 2 92 bs hr 1 32 kg hr 1 68 kg hr 0 24 Ib hr 8 18 Ibs hr 0 11 kg hr 3 71 kg hr 4 70 kg hr 0 61 lb hr 11 0 Ibs hr 14 0 Ibs hr 0 27 kg hr 4 99 kg hr 6 36 kg hr 1 25 Ibs hr 37 04 Ibs hr 47 10 Ibs hr 0 57 kg hr 16 80 kg hr 21 36 kg hr 3 08 kg hr 0 44 Ib hr 14 96 Ibs hr 0 20 kg hr 6 79 kg hr 8 63 kg hr 1 12 Ibs hr 19 60 Ibs hr 25 63 Ibs hr 2 20 Ibs hr 67 44 Ibs hr 85 90 Ibs hr 1 00 kg hr 30 59 kg hr 38 95 kg hr 0 44 Ib hr 5 34 Ibs hr 0 20 kg hr 2 42 kg hr
23. 2 100 00 12 jx 213920302 10000 12 pp 30250040 25mm DT 30 204010 175 00 Additive Sample weighing Weighing samples of additive provides for more precise control of feed rate Up to 5 samples can be weighed All weights entered are averaged to arrive at a value to be used during operation The weighing process may be skipped altogether in which case the calibration weight 1s used for calculations of feed rate Weight Calibration The final step of recipe setup is weight calibration This procedure 1 common to all types of presses supported After entering the calibration weight pressing the Next button displays the following screen 882 01749 00 27 of 93 PRESS MEST TO WEIGH ADDITIVE SAMPLES PRESS TO SEIB Fev Press the Menu button to skip weighing procedure and use the calibration weight for feed rate calculations Note that using the calibration weight is not as accurate as weighing samples Pressing the Next button displays screen 1 Screen 1 TARE SAMPLE TRAY THE PLACE IN CALIBRATION BOX PRESS NEAT Prev Next Initial preparation for weighing samples The access cover to the calibration chamber should be removed opened The container used to catch and hold the samples should be tared place the container on the scale and zero the scale The container should then be placed the calibration chamber Press Next when these steps have been
24. 53 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 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 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST 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 CST 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 Sterling Inc 2900 S 160 Street New Berlin WI 53151 www sterlco com 882 01749 00 92 of 93 882 01749 00 93 of 93
25. 71 of 93 Installing the Dosing Module 1 Remove the screw M6 x 30 or 60 from the center hole 2 Place the dosing disc the dosing unit housing 3 Screw the dosing disc in place with two 2 M6 x 30 socket screws ensuring they are tight 4 Re install the center M6 x 12 socket screw to prevent pellets from getting stuck in the hole 5 Install the shear verifying that the fasteners are tight 6 Turn the dosing disc to verify smooth rotation If the disc drags on the shear the shear may have to be loosened and re positioned or replaced 7 Position the hopper on the dosing module 8 Tighten the profile clamp 9 Position the dosing unit on the dosing motor aligning the guide pins 10 Close the toggle latches fastening the dosing module to the motor assembly Installing Different Types of Dosing Discs Dosing discs of the same type and thickness except 72 pocket may be exchanged for each other If dosing discs with a different compartment number or thickness are installed the new calibration number needs to be entered into the controller 1 Enter the preliminary calibration value of the newly installed dosing disc 2 Repeat the calibration procedure to determine the final calibration value See Appendix D Spare Parts List on page 61 for disc part numbers 882 01749 00 72 of 93 Dosing Module Pellets and Some Regrind DT DISK AND HOUSING FOR DONG MASRO PELUETS AND GRANULAR ADOT WES
26. APTER THE LOADERS 10 Pr eS 4 4 iE HOPPER TS HOSPER ATIERIBLT AIEMBLT EECUSERT OF UT 7 DD amp DP HOPPER ASSEMBLIES UTE ACE ALC p CLIO AT CHINO UM ES A CE HOPPER ACTU DU A 1 CURE TO HAGE CAU TO HOFFER BET DC AECUDO A OO ae MOUNTA HART 2 A B22 00429 00 ABE PE 27 Pri BOL 3722 38 EEQUEFD Ae iring j 1 Door HO 1 184104 AE A Do FLAMCUE ada HOPPER HOPPER ATIS T LIO L AMO BOR te faac BOUL SEANG DT HOPPER ASSEMBLIES 1 D Urat 882 01749 00 65 of 93 ALUMINUM SUPPLY HOPPER A MCHRITL Ahi pil ASTA 1 MT Cue See APN Agar ADART DO fee PLACE BLO Os ADUNI HEPIE GOD ao DF E PAP Le Eb ij
27. E INTEECHANGABLE IICLUDING T 72 POC AND ACCOMPAHNTIHO HE F FREQUENT CHANGES ARE PSQUIED IT A CONSIDERABLT FASER A SEPARATE OGE AND Y WOW HOPPER CALBPARON GOX ASIEM Y Y PEMOWING box 8 81 TRAY PART 6 ANDREO AS THE Uhl AN AMOUNT MATERIAL WEL PALL INTO mW RAT OVER A OWEN AMOUNT OF Creve THE CONTROL AM ACCURATE GAGE LATCH ALLOW BART BERS AL ARD OF THE DEE AMD HINES IED s 882 01749 00 69 of 93 4 2 Removing the shear 1 2 3 Removing the Shear Plate DD dosing Module Turn off the On Off switch Disconnect the power supply Open the toggle latches on the dosing motor Remove the dosing unit from the dosing motor Empty the dosing station Open the profile clamp B on the dosing hopper Dosing unit sida view Remove the dosing hopper from the dosing feeder Loosen the two screws C on the underside of the dosing unit housing E Remove the shear A Installing the shear l 2 Place the new shear in the dosing unit housing and ensure that it 1s positioned correctly Bolt the shear in place with the two 2 hexagon M5 x 16 socket screws and lock washers Turn the dosing disc to verify smooth rotation Repl
28. ETAIL 118 DC MTR CONTROL 6120 240 119 1CTL 170 121 122 Me KB KBWS 25D 173 123 174 124 125 175 PLC SPLY 176 Ji 4 126 120VAC i 180VDC a seg 95 178 128 179 129 180 ABLE 130 131 y DISPLAY 089 CONNECTOR 1 132 zo 184 0090090 134 135 185 ina RED 136 187 MOTOR CONNECTOR 137 18GA BLU 4 186A a 188 138 189 139 190 140 RED 191 24 141 192 142 143 195 ENCODER 194 144 195 us 196 24V ENCODER 146 s BODINE MOTOR 201 1 6HP 1 3 2 240C 7 D 4 10 198 148 26 0 1 GROUNDED NEUTRAL REQUIRED IN SUPPLY POWER FOR 115V ONLY 199 149 LEGEND TERMINAL BLOCKS LOCATED OUTSIDE ENCLOSURE SCHEMATIC LINE NUMBER REF FIELD WIRING OPTIONAL FEATURES 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 LEGEND _ 24 10 235 10 24VDC TERMINAL BLOCKS XXX SCHEMATIC LINE NUMBER REF LOCATED OUTSIDE ENCLOSURE FEEDER RUN TO PRESS MTR INHIBIT UNUSED UNUSED POWER OFF INHIBIT RELAY ALARM RELAY FPX 14 PLC INPUTS 1 8 COM e XO X1 2 OPTIONAL FEATURES 7 FEEDER ENCODER SEE SHEET 1 ALTERNATE ENCODER 7 ALTERNATE ENCODER 2 ALTERNATE ENCODER 3 REMO
29. Selection Select simple extrusion 882 01749 00 17 of 93 RPM 44 8 Maximum Motor speed Enter motor RPM ENCODER 42345 POLSES Prev Next Done Encoder pulses per disk revolution See table Motor Color Encoder Pulses Bodine Black amp silver Bodine Black amp silver Bodine Black amp silver Bodine Black amp silver Pe Motor and alarm utilty selection 882 01749 00 18 of 93 le fault Iueazure 882 01749 00 Drive tuning Perform drive tuning See section for details 1 2 11 54 E RPh Speed Alarm setup Select alarm option Alarm amp stop alarm only or no alarm peed Deviation 5 Alarm Delay 2 Sec ALARM vene DEFAULT ADDITIVE MEASURE Prev Nex bone GR or OZ Select the measure commonly used at your facility DEFAULT THROUGH PUT MEASURE Extrusion Press GR KG OZ LB Select the measure commonly used at your facility ADDITIE WATER LAL SENSOR SENSOR Additive sensor Select the no sensor alarm only or alarm amp stop 19 of 93 WATER LAL SENSOR SENSOR Virgin material sensor Select the no sensor alarm only or alarm amp stop Recipe Setup for Simple Extrusion 1 Turn power switch to ON position In order to calculate the correct motor speed required to feed the desir
30. Sterling Digital Dosing Disc Additive Feeders single Duo and Trio With A250 Controller Part Number 882 01749 00 Bulletin Number BF3 600 5 Effective 12 17 10 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 2011 All rights reserved 882 01749 00 Shipping Info Unpacking and Inspection You should inspect your granulator for possible shipping damage Thoroughly check the equipment for any damage that might have occurred transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading 15 attached to our original invoice If the shipment was prepaid write us for a receipted
31. TE START STOP SCREW RECOVER INJECTION EXTRUDER RUN SIMPLE EXT ADDITIVE PROBE VIRGIN PROBE KB KBWS 25D 24 PWR OFF INHIBIT A 234 ALARM RELAY 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 261 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 INJECTION MOLDING SIMPLE EXTRUSION AFPX DA2 ANALOG 2 OUT MTR SPEED SIGNAL KBWS 25D EXTRUSION FOLLOWER 21 0 10V PRESS SIGNAL 0 20 ANALOG 2 IN 1 OUT 4 20mA PRESS SIGNAL 51 52 51 51 PHS 54 OUT 54 OUT S S COM COM 53 E REMOVE J1 amp J2 54 92 RETAIN J1 amp 42 MTR SPEED SIGNAL KBWS 25D Appendix D Spare Parts List Dosing Disc Shear Order Numbers Dosing disc wear resistant 18 25 and 40 pocket disc ee Replacement Motor Assembly Part Numbers Gear Motor Assemblies Bauer Bodine N A 3 RPM 892 02095 00 6 4 RPM 8 4 RPM CT34300 11 5 RPM 11 5 RPM CT102241 35 5 RPM 38 RPM CT34299 NOTE Bauer blue and Bodine black amp silver motors are mechanically interchangeable with changes to controller parameters 7 and 8 See page 20 amp 21 882 01749 00 91 of 93 Appendix E Technical Assistance Parts Department Call toll free 7 5 CST 800 423 3183 or call 262 641 8610 Fax 262 641 86
32. The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value initially displayed is the weight which would result a motor speed of 25 The valid range of values would then to 2 5 times this initial value Additive Sample weighing Weighing samples of additive provides for more precise control of feed rate Up to 5 samples can be weighed All weights entered are averaged to arrive at a value to be used during operation The weighing process may be skipped altogether in which case the calibration weight is used for calculations of feed rate See the section Weight Calibration at the end of this section Extrusion Follower Recipe In order to calculate the correct motor speed required to feed the desired amount of additive the following data must be entered 1 Additive 5 Throughput 6 Throughput RPM 7 Calibration weight In addition for the greatest accuracy samples of the additive should be weighed and entered Additive Additive F F0 882 01749 00 39 of 93 The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the throughput is 200 grams per minute and 8 5 grams of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Throug
33. This guide is to be used for general disc selection for Digital Dosing unit applications All rates shown are based on continuous throughput of free flowing materials Consult factory for regrind powder and all hard to flow materials Minimum recovery time is one 1 second and maximum rate is 9 5 disc revolutions in one screw recovery cycle injection mode Use correct disc for molding applications to ensure proper dispensing of material during the recovery cycle Feeder should not run continuously below 15 of maximum speed use lower RPM motor or disc with smaller pockets 35 5 and 38 rpm motors can only be used with soft pellets may not have enough torque to cut hard pellets i e PC PET nylon etc especially when the shear gets dull 882 01749 00 85 of 93 Disc Min Max Amount of Material Dispensed Minimum Throughput Maximum Throughput Nomenclature Disc RPM every Disc Revolution Continuous Running Continuous Running 3 RPM 0 34 kg hr 0 43 kg hr 5 04 kg hr 6 4 kg hr 18 mm dia 8 4 RPM 28 0 g rev 35 6 g rev 0 34 kg hr 0 43 kg hr 14 11 kg hr 17 9 kg hr Default 20 holes 05RPM l 48ghole 1 85 Ibs hr 2 31 Ibs hr 42 23 Ibs hr 52 7 Ibs hr 28 00 g rev CT23056 1 0 RPM 3 7 Ibs hr 4 70 Ibs hr 140 76 Ibs hr 179 0 Ibs hr Sure shot 3 RPM 0 40 kg hr 0 50 kg hr 5 94 kg hr 7 5 kg hr Oval Hole 8 4 RPM 33 6 g rev 42 7 glrev 0 40 kg hr 0 50 kg hr 16 63 kg hr 21 1 kg hr ODE ZO x 2481bs hr 2 771bs hr
34. ace shear if it is dragging on disc when disc is rotated Position the dosing hopper on the dosing module and install the profile clamp B Tighten the M10 hex head screw on the profile clamp Position the dosing unit on the dosing motor aligning the guide pins Close the toggle latches fastening the dosing module to the motor assembly 882 01749 00 70 of 93 4 3 Removing the DD Disc and Cleaning the Dosing Module Dismantling the Dosing Module 1 Switch the control unit Off with the On Off switch 2 Disconnect the power supply 3 Open the toggle latches on the dosing motor 4 Remove the dosing unit from the dosing motor 5 Empty the dosing module 6 Open the profile clamp on the Dasing unit flop view dosing hopper 7 Remove the dosing hopper from the dosing module 8 Dismantle the dosing module and remove the shear D as described above in 5 2 9 Loosen and remove the two M6 x 30 socket screws C on top of the dosing disc A 10 Remove the center M6 x 12 socket screw B and replace with an M6 x 30 or 60 screw 11 Lift the dosing disc A from the dosing unit housing B by tightening this screw 12 Clean the shear plate with a cotton cloth 13 Clean the dosing hopper and the rm dosing disc in soapy water LI 14 The dosing unit housing may also be cleaned with a soft cloth keeping liquids out of the bearings Dasing unit side view 882 01749 00
35. chine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor 882 01749 00 7 of 93 1 4 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI NEPA or CE and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer M Follow all SAFETY CODES Keep fi
36. cipe validation and feed rate calculation If samples are not weighed as described in the next section this value is used during operation The weight can be entered in ounces or grams The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value initially displayed is the weight which would result in a motor speed of 25 The valid range of values would then be 4 to 2 5 times this initial value DD Pellet Discs Calibration Number No of Pockets Disc Thickness DD 30 051818 15 00 882 01749 00 21 of 93 DT Pellet amp Regrind Discs Calibration No of 8 DP Powder Discs Number Pockets DT 30 101820 32 00 2 Duc Calibration Disc 10 mm DT 30 102025 Number Thickness Sure shot 20 20 Oval DP 30 050940 oval holes 38 00 30 203012 100 00 71392902 10000 12 250940 DT 30 204010 175 00 Feeder Configuration Extrusion follower Touch the ACS logo on the main menu screen to access the configuration menu See section for details Feeder EXTRUSION FOLLOWER Feeder Type Selection Select extrusion follower 0 10 VOLTS Select press signal type 0 10V 0 20 or 4 20mA 882 01749 00 22 of 93 SIGNAL 1 2 125 4 oram Enter Read Minimum press signal
37. completed The motor will begin to run as Screen 2 will be displayed Screen 2 PRIMING ADDITIVE PLEASE WAIT PRESS TO CANCEL The disc will make one complete revolution insuring all pockets are filled with additive material prior to actual weighing Motor speed is 25 Screen 3 DISCARD SAMPLE REPLACE TRAY CALI BRATION BOS PRESS NEAT When motor stops screen 3 15 displayed Discard sample and replace container in calibration box Press Next starts the motor and displays Screen 4 882 01749 00 28 of 93 Screen 4 LOADING WEIGHT SAMPLE PLEASE WAIT PRESS MENU TO CANCEL The disc will make one complete revolution dispensing additive into the tray Motor speed is 25 When the motor stops Screen 5 is displayed Screen 5 WEIGH SAMPLE E REPLACE TRAY IN CALI BRATION BOX PRESS MEXT Prev Des Weigh the sample making note of the weight for entry on the next screen Discard sample amp replace tray in calibration box Press Next to display Screen 6 Screen 6 ENTER SAMPLE WEIGHT 12 34 Enter the sample weight obtained from the previous cycle of the feeder The unit of measure will be the same as used for the calibration weight Pressing the Enter symbol on the screen keypad displays Screen 7 882 01749 00 29 of 93 Screen 7 TO CONTINUE 12 34 GR 1 OF 5 SAMPLES Th
38. d shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long term service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine 15 provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result i
39. ditive feeder The feeder precisely meters and controls the addition of color concentrates master batches additives regrind and other materials to plastic processing systems The Digital Dosing feeder can meter pellets micro pellets prill powder and granular material of various sizes when equipped with the appropriate dosing module It can be used on extruders and blow molding and injection molding machines Single or Dual Station feeders are the most popular but three and four component models are also available See Figures and 2 This manual covers the installation and operation of all of these feeders Figure 1 Single Station Digital Dosing Feeder and A250 Controller 882 01749 00 9 of 93 325 mm 12 8 320 mm 12 6 Figure 2 Duo Dual Station Digital Dosing Feeder 2 1 250 Controller The Digital Dosing additive feeder consists of a controller s dosing motor s and dosing module s The controller 1s used to Configure the feeder to the desired process Calibrate the feeder Run monitor and stop the dosing feeding process Enter recall and run recipes Troubleshoot problems via touch screen A touch screen is used to enter modify and display data The control system is switched On position 1 with the On Off switch 882 01749 00 10 of 93 2 2 Quick Start Up Guide See Chapter four for complete description This Quick Start section is intended to help you start
40. e correct motor speed required to feed the desired amount of additive the following data must be entered 1 Additive 2 Throughput 3 Throughput RPM 4 Calibration weight In addition for the greatest accuracy samples of the additive should be weighed and entered Additive Additive F F0 The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the throughput is 200 grams per minute and 8 5 grams of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Throughput screen 882 01749 00 25 of 93 Throughput ilM Prev Press throughput specifies the total weight of material through the extruder per minute The value can be entered in grams kilograms ounces or pounds per minute The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen This value is the throughput corresponding to a specific extruder RPM which will be entered on the following screen Given these reference values the correct feed rate can be determined for any extruder speed Note that the minimum and maximum press speeds and signal levels must be entered correctly in Setup 123 Throughput Speed The press speed corresponding to the thro
41. e each individual section for details Once the feeder is on line recipes can be saved for later recall up to 50 standard 882 01749 00 34 of 93 3 3 Recipes Recipe Menu Recipe Menu Recipe Edit Recipe The Recipe menu allows selection editing and deletion of recipes The current recipe is displayed in the upper left corner A different recipe can be selected by pressing the recipe value Selecting a new recipe will automatically change the screen to the 1 recipe entry editing screen Pressing the Edit Recipe button will display the 1 recipe entry edit screen See following section Pressing the New Recipe button will display the New Recipe menu _ Recipe _ Edit Recipe Pressing the Edit Recipe button will display the 1 recipe entry edit screen See following section Select a new recipe by pressing the recipe value Press the Next Avail button to use the next available empty unused recipe number Pressing the Delete Recipe button will display a confirmation screen as follows 3 CONFIRM DELETE RECIPE Delete Keep Recipe Press the Delete Recipe button to clear all values from the current recipe Pressing the Keep Recipe button will retain the values and return to the Recipe Menu screen 882 01749 00 35 of 93 Enter Edit Recipes Injection molding In order to calculate the correct motor speed required to feed the
42. e screen displays the running average of sample weights as well as the number of samples taken Pressing Next will repeat the process at Screen 4 if less than 5 samples have been taken otherwise Screen 8 will be displayed Screen 8 RAWOVE TRAY REPLACE SAMPLING COMER PRESS MEST The tray should be removed from the calibration chamber The access cover should be replaced closed Weight Calibration 1s complete Note that at any time in the process the Menu button may be pressed to abort the weight calibration process Any sample weights if any are used to calculate the average weight If no sample weights are entered the calibration weight is used for calculations Using less than 5 samples may affect feeder accuracy 882 01749 00 30 of 93 Chapter 3 Installation and Operation 3 1 Installation Hopper Piece Prdcessing Machine l Direction of Material Flow Figure 4 Digital Dosing Feeder Assembly 1 The Digital Dosing additive feeder is not affected by machine vibration so the best performance is achieved by mounting the feeder directly on the feed throat of the molding machine or extruder see Figure 4 The inlet into the process machine must be greater than 2 diameter or an adapter may be necessary If an adapter is required it must be designed so that there are no edges where material can hang up it must be smooth to promote consistent material flow 882
43. ed amount of additive the following data must be entered 1 Additive 2 Throughput 3 Calibration weight In addition for the greatest accuracy samples of the additive should be weighed and entered Additive Additive F F0 vex The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the throughput is 200 grams per minute and 8 5 grams of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Throughput screen 882 01749 00 20 of 93 Throughput 123 m b5E Prev Press throughput specifies the total weight of material through the extruder minute The value can be entered in grams kilograms ounces or pounds per minute The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen It is important that this value be adjusted whenever the extruder speed changes Calibration weight Recipe Calibration Weight 12 58 Prev E ves en Calibration weight 1s determined from the following tables and 1s dependant on the disc installed in the feeder This weight 1s the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for re
44. eparation for weighing samples The access cover to the calibration chamber should be removed opened The container used to catch and hold the samples should be tared place the container on the scale and zero the scale The container should then be placed the calibration chamber Press Next when these steps have been completed The motor will begin to run as Screen 2 will be displayed 882 01749 00 41 of 93 Screen 2 WITH ADDITIE PLEASE WAIT PRESS TO CANCEL The disc will make one complete revolution insuring all pockets are filled with additive material prior to actual weighing Motor speed is 25 Screen 3 DISCARD SAMPLE REPLACE TRAY IN CALI BRATION BOS PRESS HEST When the motor stops screen 3 is displayed Discard sample and replace container in calibration box Press Next starts the motor and displays Screen 4 Screen 4 LOADING WEIGHT SAMPLE PLEASE WALT PRESS MENU TO CANCEL The disc will make one complete revolution dispensing additive into the tray Motor speed is 25 When the motor stops Screen 5 is displayed 882 01749 00 42 of 93 Screen 5 WEIGH SAMPLE E REPLACE TRAY IN CALI BRATION BOX PRESS MEST Prev Weigh the sample making note of the weight for entry on the next screen Discard sample amp replace tray in calibration box Press Next to display Screen 6 Screen 6
45. ghten the profile clamp 882 01749 00 74 of 93 4 5 Removing the DT Disc and cleaning the dosing station 1 Switch the control unit with the On Off switch 2 Disconnect the power supply 3 Open the toggle latches 2 Remove the dosing hopper D from the motor 3 Empty the dosing station 4 Open the profile clamp C 6 Remove the profile clamp C 7 Remove the dosing hopper assembly A and B 6 Remove the two M6 x 30 socket screws B on top of the dosing disc A 7 the dosing disc A from the dosing unit Toggie lype fasiener housing 8 Clean the components with a cotton cloth 9 Clean the dosing hopper A and B in soapy water 10 Dry all parts thoroughly 11 Install the dosing hopper on the dosing module locating the guide pin 12 Install the profile clamp and tighten the screw 13 Mount the dosing housing onto the dosing motor Dasing unit side view 14 Close the toggle latches securing the dosing module to the motor assembly 882 01749 00 75 of 93 DP Powder Dosing Module siet Dum 3 2818 ACHAT Cet PREVENTI DP DISK AND HOUSING FOR DOSING POWDER ADCITVES EN ET AT Tex coves RO a lipe
46. hine The connection in the controller should be on terminal block 10 and PLC input X5 882 01749 00 11 of 93 6 EXTRUSION Simple Connect the input cable 2 conductor cable gray to a dry contact zero voltage signal that indicates the extruder screw 15 turning The connection in the controller should be on terminal block 10 and PLC input X5 A jumper wire can also be installed on the same terminals instead of a dry contact if the feeder is to be started and stopped through the feeder controller and not with the extruder screw 7 EXTRUSION Follower Connect the input cable 2 conductor cable gray to a 0 10 VDC 0 20 mA or 4 20 mA signal from the extruder that indicates the screw speed rpm of the extruder The connection inside the controller should be on terminals blocks Sland 54 Feeder Configuration Injection Molding Touch the ACS logo on the main menu screen to access the configuration menu See section for details Feeder INJECTION MOLDING foo Feeder Selection Select injection molding default value RPM 44 8 Maximum Motor speed Enter nominal motor speed 882 01749 00 12 of 93 ENCODER 42345 PULSES Prev Nex Done Encoder pulses per disk revolution See table Motor Color Encoder Pulses Bodine Black amp silver Bodine Black amp silver Bodine Black amp silver Bodine Black amp sil
47. hput screen Throughput Prev Press throughput specifies the total weight of material through the extruder minute The value can be entered in grams kilograms ounces or pounds per minute The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen This value is the throughput corresponding to a specific extruder RPM which will be entered on the following screen Given these reference values the correct feed rate can be determined for any extruder speed Note that the minimum and maximum press speeds and signal levels must be entered correctly in Setup 123 Throughput Speed The press speed corresponding to the throughput value entered on the previous screen Given these reference values the correct feed rate can be determined for any extruder speed Note that the minimum and maximum press speeds and signal levels must be entered correctly in Setup Calibration weight Recipe Calibration Weight 12 3 882 01749 00 40 of 93 Calibration weight is determined from chart 5 1 and is dependant on the disc installed in the feeder This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for recipe validation and feed rate calculation If samples are not weighed as described i
48. indow within which the motor speed must be for normal operation The Alarm Delay specifies the minimum time the speed must be outside this window before generating an alarm For example if the default values are used and the commanded speed is 5 RPM the controller will alarm if the speed is less than 4 75 RPM or more than 5 25 RPM for at least 2 seconds The specific response to the alarm condition can be selected by pressing the button in the lower left corner as follows ALARA Take no action See Status screens for indicator ALARM Activate alarm screen amp alarm output on PLC 882 01749 00 56 of 93 ALARM 5 Activate alarm screen amp alarm outputs and stop the feeder See Status Screens section for speed alarm screen details Default Additive Measure DEF AULT ADLDITIvE MEASURE Prev Nex pene This screen sets the default measure for additive weight in recipes While the measure can be changed in any recipe this screen allows selection of the most commonly used unit of measure Press the upper right corner to select Grams Or Ounces 882 01749 00 57 of 93 Default Shot Size Throughput Measure DEFAULT SHOT SIZE MEASURE PUT MEASURE Injection Press Extrusion Press DEFAULT THROUGH This screen sets the default measure for overall weight in recipes While the measure can be changed in any recipe this screen allows selection of the most commonly used unit of
49. iscs Calibration Number Disc Number of Thickness Pockets DP 30 250940 882 01749 00 79 of 93 4 9 Spare Parts DD Dosing Units QTY U M DESCRIPTION 5 reeset GASKET COVER CAL BOX CDKICDD T erate SHEARCDDIOCBQSB 8 C2 TEA V CLAMPDTS0 DISCIINTERMEDIATE 5 2EA SCREW SOCKET 5 16 2EA WASHER LOCK M5 CT21392 ALL OTHER DISCS 5MM a a 882 01749 00 80 of 93 DT Dosing Units f 20 POCKET DISK STANDARD DEEP uw lS TEA 5 TEA 5 6 1 192228 1EA V CLAMP DT30 DISC INTERMEDIATE 8 100029 116 4EA SCREW PAN PHILLIPS M4X12 9 CT11863 1 MOUNT CALIBRATE TUBE CDK CB SB 10 CT100031 147 BEA SCREW HEX M6X35 11 CT100034 147 1 WASHER FLAT M6 WASHER FLAT M5 CALIBRATION TUBE CDK CB SB DISC DT30 20 POCKET SURE SHOT CT23060 DISC DT30 12 POCKET 20MM DEEP CT18405 DISC DT30 10 POCKET 20MM DEEP CT100031 149 SCREW HEX M6X35 CT66121 DISC HOUSING DT30 20MM 20MM DEEP DISKS REQUIRES LONGER MOUNTING SCREWS DEEPER HOUSING 882 01749 00 81 of 93 DP Dosing Units 5 10 m LE 12 13 14 15 16 4 EA 17 18 19 20 21 22 23 24 25 26 27 28 29 30 LEA 31 CT66864 TRAY CAL BOX 882 01749 00 82 of 93 DD DT DP Additional Spare Parts ITEM PART NO U M DESCRIPTION Le 892 01046 00 COVER WITH KNOB SS FOR ACRYLIC HOPPER
50. ll the dosing station until the level sensor 15 one third covered 3 Remove the plastic screw M3 on the back of the level sensor see Figure 7 882 01749 00 63 of 93 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 Cable Level Probe Figure 7 Level Sensor Adjustment Screw 4 Turn the trim pot until the yellow control lamp just switches off NOTE Turning the trim pot to the left decreases the switching sensitivity and turning it to the right increases the sensitivity 5 Hill the dosing station until the level probe 1s 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 0 882 01749 00 64 of 93 Communication Protocol Interfaces The Digital Dosing feeder can be controlled remotely through ODBUS RTU protocol Contact the sales Department at 810 720 7300 for more information OPTIONAL Additive Hoppers Various styles of additive hoppers and options are also available for the Digital Dosing feeder Contact the Sales Department at 810 720 7300 for more information ACRYLIC SUPPLY HOPPERS POO 24 87250732150 AD
51. mm diameter 8 4 RPM 15 6 g rev 19 5 g rev 0 187 kg hr 0 23 kg hr 7 86 kg hr 9 82 kg hr 40 pockets 0 5 RPM 0 3 g hole 0 4 g hole 1 00 Ib hr 0 12 Ib hr 22 62 Ibs hr 28 65 Ibs hr 15 00 g rev CT100863 11 5 RPM 0 45 kg hr 0 57 kg hr 10 62 kg hr 13 80 kg hr 1 0 RPM 2 00 Ibs hr 2 60 Ibs hr 78 57 Ibs hr 98 16 Ibs hr 38 RPM 0 94 kg hr 1 17 kg hr 35 64 kg hr 44 52 kg hr 882 01749 00 86 of 93 Appendix C Drawings Single Station Digital Dosing Feeder 180 21 4 Eit A E 150 mm 95 4 3 1 7 N bs 1112 ITI A 0 6 366 mm 14 4 TOP VIEW SIDE VIEW 87 of 93 882 01749 00 Duo Digital Dosing Feeder SIDE VIEW TOP VIEW 88 of 93 882 01749 00 Electrical Schematics of A250 Controller TO USERS FUSED 15 CIRCUIT 150 100 115 220 UNE L2 OR 115V NEUTRAL 151 101 NOTE 1 102 L2 SW 220V ONLY 220 ONLY 152 CRN WHT WHT BRN a 2FU 220V 1 2 2 GRD 153 103 L2 1 imi NOTE 1 L 3 10 154 104 155 WHT BLU SHIELD e M 4 156 120 220V 106 16GA WHT 14GA BLK 157 107 aL 158 108 EARTH GND 4GA BLK 220V 159 109 5 160 110 XUL a 16GA RED 120V 161 BRN WHT WHT ORN 112 d ALARM HORN 14 246 163 113 D 164 ORN WHT WHT GRN 114 165 ISPLAY CABLE DIAGRAM 115 ALARM LIGHT 0 BLU WHT 116 117 UN DRIVE AC SPLY 168 089 CONNECTOR D
52. ms of additive are required the additive percentage would be 4 25 After the additive value has been entered press the Next button to navigate to the Shot Size screen Shot Size The shot size specifies total capacity of the mold use on the press The value can be entered grams kilograms ounces or pounds The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen 882 01749 00 15 of 93 Screw Recovery Time The screw recovery time is the estimated screw recovery time and 15 used as the initial value for validating the recipe Actual screw recovery times as measured by the presence of the screw recovery signal are used to fine tune the feed rate during operation The estimated time must be at least 1 2 of the actual recovery time If less than 2 the feeder will interpret the recovery signal as a purge cycle Calibration weight Recipe Calibration Weight 12 38 Prev Calibration weight is determined from the following tables and is dependant on the disc installed in the feeder This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for recipe validation and feed rate calculation If samples are not weighed as described in the next section this value is used during operatio
53. n The weight can be entered in ounces or grams The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value initially displayed is the weight which would result in a motor speed of 25 The valid range of values would then be to 5 times this initial value DD Pellet Discs DD 30 051818 15 00 2 0 5 18 682 01749 00 16 of 93 DT Pellet amp Regrind Discs Disc Calibration No of DP Powder Discs Calibration Disc Disc Number Thickness Thickness Number Pockets DT 30 101820 32 00 20 10 mm DT 30 102025 Sure shot 20 20 Oval oval holes 38 00 DP 30 5mm 050940 17 00 DT 30 203012 100 00 DP 30 mm 4 00 2 5mm DT 30 204010 175 00 250940 Additive Sample weighing Weighing samples of additive provides for more precise control of feed rate Up to 5 samples can be weighed All weights entered are averaged to arrive at a value to be used during operation The weighing process may be skipped altogether which case the calibration weight is used for calculations of feed rate See the section Weight Calibration at the end of this section Feeder Configuration Simple extrusion Touch the ACS logo on the main menu screen to access the configuration menu See section for details Feeder EXTRUSION FOLLOWER Feeder Type
54. n death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or property damage 882 01749 00 6 of 93 1 2 General Safety Regulations These regulations should be read understood and periodically reviewed by all personnel involved in any way with this machine Never operate or remove any machine components that are secured by wrench type fasteners unless the motor is electrically locked out and the disc is motionless Never operate the machine unless the dosing module is in place and all guards and covers are in place and secure Prior to clearing a jam or performing any maintenance the motor should be turned off and electrically locked out Be sure that the disc has stopped Hands must not be inserted into the machine to clear the jam Never extend fingers through safety guards Be sure that the v belts are properly aligned and that tension 1s at its maximum Extreme care should be taken to see that all bolts are properly tightened at all times This machine is designed for the feeding of free flowing granular materials Do not feed any other materials into the machine without consulting with one of our Application Engineers 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the ma
55. n the next section this value is used during operation The weight can be entered in ounces or grams The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value initially displayed is the weight which would result in a motor speed of 25 The valid range of values would then to 2 5 times this initial value Additive Sample weighing Weighing samples of additive provides for more precise control of feed rate Up to 5 samples can be weighed All weights entered are averaged to arrive at a value to be used during operation The weighing process may be skipped altogether in which case the calibration weight is used for calculations of feed rate 3 4 Calibration The final step of recipe setup is weight calibration This procedure is common to all types of presses supported After entering the calibration weight pressing the Next button displays the following screen PRESS HEAT TO WEIGH ADDITIVE SAMPLES PRESS TO SEIB Prev Press the Menu button to skip the weighing procedure and use the calibration weight for feed rate calculations Note that using the calibration weight is not as accurate as weighing samples Pressing the Next button displays screen 1 Screen 1 TARE SAMPLE TRAY THEN PLACE CALIBRATION BOX PRESS NEAT Prev Initial pr
56. ngers away from rotating discs slide gates augers clean outs and calibration hatches Automatic operation may start unexpectedly A PINCH HAZARD CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power and compressed air before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications M OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you NEVER PUT FINGERS OR TOOLS IN HOPPER AUGER OR SLIDE GATE AREA M Make sure the equipment and components are properly GROUNDED before you switch on power Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 882 01749 00 8 of 93 Chapter 2 Functional Description 2 1 Introduction This manual is to be used with the Digital Dosing Disc ad
57. on 1 30 g rev DD30 051040 Default calibration 4 00 g rev 4 10 0 051725 DD3 Default calibration 4 11 DD3 0 05 ul calibration 13 50 Note 1 Note 2 Note 3 Note 4 Disc Nomenclature 030672 3 mm thick 5 7 mm diameter 72 pockets CT100562 050660 5 mm thick 5 7 mm diameter 60 pockets 822 00738 00 051040 5 mm thick 10 mm dia AO pockets CT21710 051725 5 mm thick 17 mm dia 25 pockets CT21711 051818 5 mm thick 18 mm dia 18 pockets CT23057 Min Max Disc RPM 3 RPM 8 4 RPM 0 5 RPM 11 5 RPM 1 0 RPM 38 RPM See Note 4 3 RPM 8 4 RPM 0 5 RPM 11 5 RPM 1 0 RPM 38 RPM See Note 4 3 RPM 8 4 RPM 0 5 RPM 11 5 RPM 1 0 RPM 38 RPM See Note 4 3 RPM 8 4 RPM 0 5 RPM 11 5 RPM 1 0 RPM 38 RPM See Note 4 3 RPM 8 4 RPM 0 5 RPM 11 5 RPM 1 0 RPM 38 RPM See Note 4 Amount of Material Dispensed Appendix B Disc Sizing Guides Minimum Throughput Maximum Throughput every Disc Revolution 0 02 kg hr 0 02 kg hr 0 28 kg hr 0 35 kg hr 0 02 kg hr 0 02 kg hr 0 77 kg hr 0 98 kg hr 1 53 g rev 0 02 g hole micropellets 1 35 g rev 0 02 g hole 4 24 g rev 0 11 g hole 7 37 g rev 0 30 g hole 13 42 g rev 0 75 g hole 1 95 g rev 0 027 g hole micropellets 1 70 g rev 0 028 g hole 5 39 g rev 0 13 g hole 9 38 g rev 0 38 g hole 17 08 g rev 0 95 g hole Continuous Running 0
58. output that 15 proportional to the extruder speed The signal can be 0 10 VDC or 0 20 mA or 4 20 mA Jumpers J1 J2 should be installed for 0 20mA or 4 20 and removed for 0 10VDC NOTES 1 Signal voltage from the extruder must to be isolated Consult factory for other signal requirements External signal converter may be required 2 Zero input corresponds to zero screw speed and no additive dosing Maximum input corresponds to maximum screw speed TB 51 TB 54 0 10 VDC 0 4 20 mA Extruder output Digital Dosing controller Figure 6 Analog Extruder Input Connection Diagram Extrusion Proportional 882 01749 00 33 of 93 3 2 Initial Operation The control system is factory programmed However specific values need to be verified prior to operation basic parameter settings The input values will be saved and still be available if the feeder 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 These are also explained in Appendix B Prior to putting your new Digital Dosing feeder on line Configure the feeder control for motor speed encoder pulses sensors and alarm options Tune the drive Enter a recipe Calibrate the additive weight for best accuracy NOTE Recipe parameters are different for Injection Molding Extrusion Constant and Extrusion Proportional operation Se
59. r can be connected to an alternate PLC input to help troubleshoot encoder problems To change the encoder input disconnect power amp move the encoder signal wire from input 0 to any of inputs 1 2 or 3 Restore power navigate back to this screen and change the ENC CH to match the PLC input chosen When the Jog Mtr button is pressed the motor will run at 25 speed for as long as the button is pressed The top line will display the raw encoder value The value will be 500 for KB or Bodine drives or 1000 for Dart drives The PRESS value will be 0 4000 depending on the press signal if no press signal is connected the value will be at or near zero 3 6 Optional Features Optional equipment for the Digital Dosing Additive Feeder includes Loaders Several versions of automatic loaders are available to keep the additive or virgin material supply hoppers full consult with your sales contact for the unit that best fits your needs Hoppers Several versions of hoppers are available and can be used in different applications consult with your sales contact for the unit that best fits your needs Alarms Several alarm options are available for the Digital Dosing feeder 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 Fi
60. re Default Thruput 65 Meas 6A Additive Sensor 6B Virgin Sensor 66 Press Signal Type 67 Min Signal set 68 Max Signal set 6C Passwords 6D Digital 1 Monitor 6E Analog I O Monitor 882 01749 00 Press Type Max Motor Speed Encoder Pulses Tune amp Speed alarm Default Add Measure Default Thruput Meas Additive Sensor Virgin Sensor Press Signal Type Min Signal set Max Signal set Passwords Digital Monitor Encoder Pulses Tune amp Speed alarm Default Add Measure Default Shot Measure Additive Sensor Virgin Sensor Press Signal Type Min Signal set Max Signal set Passwords Digital Monitor Analog I O Monitor Setup Menu 52 of 93 Feeder Type Feeder INJECTION MOLDING Next Done Feeder type is selected by pressing the button in the upper right corner The button text changes with each press of the button in the following order INJECTION MOLDING Default Mode SIMPLE ExTRUSION E TRUSIOHNH FOLLOWER An injection molding press provides a contact closure during the Screw Recovery Cycle or that period when the press is loading material prior to injection into the mold cavity The 2 types of extrusion presses are dependant on the input signal provided to the A250 additive feeder Simple extrusion provides a contact closure to input 5 of the PLC and it is assumed that the press is always run at the speed entered for the active recipe Extrusion follower provide
61. s an analog signal to channel 0 of the analog module which changes in relation to the speed throughput of the press 882 01749 00 53 of 93 Maximum Motor Speed RPM 44 8 The maximum motor RPM is the maximum rated speed for the motor being used with the A250 control The default nominal value is 11 5 RPM This value should be changed to reflect the actual motor RPM based on motor type and tuning results See Drive Tuning following this section Initially this value should be set to the nameplate RPM for the motor gearbox being used before proceeding to Drive Tuning 1 Turn the Accel amp Decel pots fully counter clockwise 2 Press the Min button 3 Check rotation direction Disk should turn counterclockwise 4 Swap A amp A leads With Power Off to change rotation direction 5 Press Max button 6 Adjust max pot to adjust max speed to match target value 7 Press Min button 8 Adjust min pot to adjust min speed to match target value 9 Repeat steps 5 8 until readings stabilize 10 If maximum speed value cannot be obtained change max RPM on the Maximum Motor Speed screen to match the closest value obtained on this screen Encoder Pulses ENCODER 42345 PULSES Prev Done The encoder pulses are determined by the number of encoder steps per motor revolution usually 30 multiplied by the gearbox ratio In the case of the standard motor the ratio is 190 1 so 30 X 190
62. sory screen is displayed Invalid Recipe INVALID OR INCONPLETE RECIPE 882 01749 00 44 of 93 Common Elements TOTAL ADDITIE 545 OVERSPEED um Buttons E Press the Start button to begin feeding operation using the current recipe Press the Stop button to end feeding operation Press the Next button to display the next Status screen There are 3 status screens available while the A250 is running Totalizer screen Throughput screen Motor Speed screen When the A250 is stopped 4 screen is available The Manual Run Jog screen ben Press the Menu button to display the Main Menu screen 882 01749 00 45 of 93 Speed Status Indicator If the speed alarm only option 15 selected in the configuration section the following indicators are enabled UVER SPEED Displays when the feeder speed exceeds the calculated speed by greater than that specified on the speed alarm setup screen The screen will change to a steady orange color UNDER SPEED Displayed when the feeder speed 15 less than that specified on the speed alarm setup screen The screen will change to a steady orange color HO PULSES Displayed when no encoder pulses are detected from the drive motor The screen will change to a steady orange color Displayed when calculated motor speed is greater than rated motor speed The screen will change to orange and flash in this condition BELOW fil Displayed when the
63. transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have Granulator M Bill of lading M Packing list Operating and Installation packet M Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered please contact the parts and service department at 262 641 8610 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 882 01749 00 iii Table of Contents CHAPTER 1 SAFE IUE Rar UE 6 TUE 6 Safety Symbols Used this 1 000 000001 0000000000000050000 6 1 2 General Safety Regulations nennen nnne nnns 7 1 3 ARESDONSIDINY RE UU T MM 7 t4 Wamnngs be 8 CHAPTER 2 FUNCTIONAL DESCRIPTION 9 21
64. ughput value entered on the previous screen Given these reference values the correct feed rate can be determined for any extruder speed Note that the minimum and maximum press speeds and signal levels must be entered correctly in Setup Calibration weight Calibration weight is determined from the following tables and is dependant on the disc installed in the feeder This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc This weight is used as the initial value for recipe validation and feed rate calculation If samples are not weighed as described in the next section this value is used during operation The weight can be entered in ounces or grams The unit of measure is changed by pressing the units button at the middle right of the screen Changing the unit of measure will NOT change the value displayed on the screen The value 882 01749 00 26 of 93 initially displayed is the weight which would result in a motor speed of 25 The valid range of values would then be 4 to 2 5 times this initial value DD Pellet Discs Calibration Number No of Pockets Disc Thickness DD 30 051818 15 00 DT Pellet amp Regrind Discs Disc Calibration No of Disc DP Powder Discs Thickness Number Pockets Calibration Disc DT 30 101820 32 00 Dies Number Thickness 10 mm DT 30 102025 Sure shot 20 20 Oval DP 30 050940 5mm oval holes 38 00 17 00 DT 30 20301
65. uration of the next screw recovery signal The purge mode will be cancelled at the end of the screw recovery signal or as noted below Purge Pressing the Purge button when purge mode is active will cancel purge mode Configuration Navigation The top level of System setup navigation is the System Setup Menu System Setup Menu Feed Default Done The configuration screens are grouped by similar function Each of buttons on the System Setup Menu screen will navigate to the 1 screen of each group From each configuration screen any of the following screens can be reached 882 01749 00 49 of 93 A The Main Menu using the Menu button B The System Setup Menu using the Done button C The next Configuration screen using the Next button D The previous Configuration screen using the Prev button System Setup Navigation Buttons Pre Navigates to the previous screen in the setup chain See Table 4 1 Navigates to the next screen in the setup chain See Table 4 1 Navigates to the Setup Menu screen Navigates to the Main Menu screen From the Drive Tuning screen returns to the Max RPM screen From the Speed Alarm screen returns to the Encoder Pulses screen 882 01749 00 50 of 93 Table 4 1 Injection Press Screen Title Function 60 Press Type 61 Max Motor Speed 62 Encoder Pulses Tune amp Speed 76 Default Add 63 Measure Default Shot
66. using the screen keyboard in RPM for the press The voltage associated with that speed can either be entered manually by pressing the value and entering the value on the keyboard or by pressing the number at the lower left to read the voltage level currently being sent by the press The unit of measure A or V is determined by the selection made on the Press Signal Type screen Maximum Press Signal Extrusion Follower only 882 01749 00 60 of 93 hi 11 5 RPM SIGNAL 5654 3 Prev ens This screen configures the maximum speed of the press and the analog signal associated with that speed Press the top number to enter the maximum speed using the screen keyboard in RPM for the press The voltage associated with that speed can either be entered manually by pressing the value and entering the value on the keyboard or by pressing the number at the lower left to read the voltage level currently being sent by the press The unit of measure A or V is determined by the selection made on the Press Signal Type screen Note The Minimum amp maximum press signal values are used to calculate the relationship between input signal and extruder speed Operation at speeds below the minimum and above the maximum are possible subject to input signal limits See appendix for examples Passwords Screen BeBe 15 hin setup hin aoga The passwords screen allow the entry of Operator amp
67. ver Motor and alarm utilty selection Drive tuning Perform drive tuning See section for details 1 2 11 57 e e RPM rm Speed Alarm setup Select alarm option Alarm amp stop alarm only or no alarm peed Deviation 5 Alarm Delay 2 Sec ALARM 882 01749 00 13 of 93 la fault Iueazure amnzarz 882 01749 00 DEF AULT ADLDITIvE MEASURE Prev Nex bone GR or OZ Select the measure commonly used at your facility DEFAULT SHOT SIZE MEASURE AUDIT VE WATER LAL ZEN SOR m Additive sensor Select the no sensor alarm only or alarm amp stop YIR GIH MATER LAL SENSOR SENSOR Virgin material sensor Select the no sensor alarm only or alarm amp stop 14 of 93 Recipe Setup Injection Molding Turn power switch to ON position Injection molding In order to calculate the correct motor speed required to feed the desired amount of additive the following data must be entered 1 Additive 2 Shot Size 3 Screw Recovery Time 4 Calibration weight In addition for the greatest accuracy samples of the additive should be weighed and entered Additive The additive specifies the proportion of additive to virgin material as a percentage of throughput For example if the shot size is 200 grams and 8 5 gra
68. when stopped Screw Recovery Times Screen Injection only 12 34 Avg 12 38 12 26 125 1243 Displays the 5 most recent screw recovery times latest on top as well as the simple average and weighted average 1 2 3 4 T Manual Run Jog Screen RPM SECS Fun This screen is only available when A250 control is stopped This screen provides means to purge clear additive prime additive etc RPM Decel buttons Accel Decel Pressing and holding either of these buttons will adjust the motor run speed by approximately 1 of max speed every 12 second The minimum speed is 5 while the maximum speed is 100 The default speed is 50 The speed at which the motor will run jog or purge Adjust using the Accel and 882 01749 00 48 of 93 button 1s held 18 SECS The length of time motor will run when Run Motor button is pressed Adjustable from to 999 seconds The default 15 seconds Run Pressing the Run Motor button causes the motor to run for the indicated time Pressing and holding the Jog button will run the motor at the indicated speed for as long as the fubotoar While the motor is running it can be stopped by pressing the Stop Motor button s Pressing the Purge button will cause the feeder to run at the indicated rate for the d
69. y Open the toggle latches Remove the dosing hopper D Empty the dosing station Remove the profile clamp C Remove the dosing hopper assembly A and B Remove the wiper and traverse as described above Remove the four screws from the metering disc and lift the disc from the dosing unit housing Taggie lype Clean components with a cotton cloth Clean the dosing hopper A and B in soapy water Dry all parts thoroughly Install the dosing hopper on the dosing module locating the guide pin Install the profile clamp and tighten the screw Mount the dosing housing onto the dosing motor Close the toggle latches securing the dosing module to the motor assembly 882 01749 00 78 of 93 4 8 Exchangeable Dosing Modules Dosing discs of the same type 1 DD may be exchanged for each other The 72 pocket also requires a different shear plate If dosing discs with a different compartment number are installed the new calibration number needs to be entered into the controller 2 Enter the preliminary calibration value of the new dosing disc or module 3 Repeat the Calibration procedure to determine the final calibration value DD Discs Disc Calibration Number of Number pockets DD 30 051818 15 00 DT Discs Disc Calibration Number of Number Pockets DT 30 101820 32 00 DT 30 102025 Sure shot 38 00 20 Oval DT 30 203012 100 00 12 DT 30 204010 175 00 DP D
70. your Digital Dosing feeder quickly and easily Please refer to the enclosed O amp I manual for additional information Unpacking 1 Inspect package for damage and notify carrier immediately DO NOT ACCEPT EQUIPMENT IF PACKAGING IS DAMAGED File a claim with the shipping company immediately if damage is evident Unpack box making sure all parts indicated on packing list are included Check all parts and equipment for any damage sustained during shipment If any damage is noted contact manufacturer for replacement or service dh doe M xo Make sure the following are present before proceeding M Power 110 or 220 volt single phase 50 or 60 hertz verify voltage on S N tag Proper mounting flange adapter and mounting hardware for the feed throat Dry ZERO VOLTAGE contact that closes during screw recovery of IMM Gram scale to measure weight of additive material for calibration Mounting 1 Mount the feeder including the dosing hopper on the feed throat may need an adapter Be sure to use appropriate fasteners to secure the feeder in place 2 Connect the motor drive connector Amp connector black to the motor 3 Connect the communication cable DB 9 plug silver to the DB 9 connector on the motor junction box 4 Plug power cord into appropriate outlet 5 INJECTION MOLDING Connect the cycle run cable 2 conductor gray to a dry ZERO VOLTAGE contact that closes during the recovery cycle of the mac

Sterling 882.01749.00 Welder User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents