SDD Series Digital Dosing
Additive Feeders
Part Number: 882.00276.00
Bulletin Number: BF3-600.2
Effective: 11/01/06
Write Down Your Serial Numbers Here For Future Reference:
_________________________
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change
without notice.
DCN No. ____________
© Copyright 2006
All rights reserved.
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Section 1: Introduction
This User’s Manual is intended for use with the Digital Dosing Disc Additive Feeder. The
feeder precisely meters and controls the addition of master batches, chemical additives, and
regrinds to primary plastics. The Digital Dosing unit can meter both powder and granular
material of various sizes. It can be used on extrusion, blow molding and injection molding
machines. Depending on the application and throughput, two models are available: Single
Station Digital Dosing Unit or Dual Station Digital Dosing Unit. See Figures 1 and 2. This
manual covers the operation of both units.
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T
P
A
G
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Figure 1. Single Station Digital Dosing Unit
(Shown with optional virgin supply hopper and controller mounting plate)
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Figure 2. Dual Station Digital Dosing Unit
(Shown with optional virgin supply hopper and controller mounting plate)
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1.1 Controller
The Digital Dosing additive feeder consists of a controller(s), dosing motor(s), and feeder(s).
The controller is used to:
• Configure the unit to the desired process.
• Calibrate the feeder
• Run, monitor, and stop the dosing process
• Enter, recall, and run recipes
• Troubleshoot problems via error codes
A keypad and LED display (see Figure 3) are used to enter, or change, data.
• The control system is switched on (position “1") with the On/Off switch. (A)
• The control system is operated through the keypad. (B)
• The individual operating modes are indicated by symbols. (C)
• Messages appear on a 5-digit LED display. (D)
Figure 3. Keypad and LED Display
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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.
Must be pressed simultaneously with the up- or down-arrow.
Run: Starts the continuous operation (LED is lit up) or calibration mode (LED
flashes)
Calibration Key: Switches from operation to calibration mode. LED flashes
when calibration process has started.
Input: Selects the next screen for the input of program parameters.
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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 control (tracking, or following)
Lights when an alarm occurs.
Percent additive
Kilograms
Grams
Pounds
Minutes
Seconds
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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. Make sure the following are present before proceeding:
; Power source 110 or 220 volt, single phase, 50 or 60 hertz (verify voltage on
Serial Number tag
; Proper mounting flange adapter 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 complete unit, including dosing hopper full of material, on the feed throat
(may need an adapter for feed throat).
2. Identify the motor drive connector (“Amp” connector-black) and connect to motor.
3. Identify the communication cable (DB-9 plug-silver) and connect to DB-9 connector
under motor drive assembly.
4. Identify power cord and plug into appropriate outlet.
5. INJECTION MOLDING: Identify the cycle/run cable (2-conductor cable-gray) for
connection to a dry (ZERO VOLTAGE) contact that closes during the screw recovery
cycle of the molding machine.
6. EXTRUSION: Identify the input cable (2-conductor cable-gray) for connection to 0-10
VDC or 0-20 mA signal that indicates speed (rpm) of the extruder.
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Recipe Setup for Injection Molding:
1. Turn power switch to ON position.
2. Press Input
3. Press Input
to display # 1, “Additive %”. Using arrow keys, set additive ratio.
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/pounds.
4. Press Input to display # 3, “Screw recovery time”. Using arrow keys, set the
screw recovery time (in seconds).
5. Press Input to display # 4, “Calibration weight for additive”. Enter the appropriate
value from the range table below and proceed to calibration mode below for calibration
of additive material.
DD Discs
Disc
Calibration Number
Range
1.75
DD 30-030672
DD 30-051040
DD 30-051725
DD 30-051818
5.00
8.00
15.00
DT Discs
Disc
Calibration Number
Range
DT 30-101820
DT 30-102025
DT 30-203012
DT 30-204010
32.00
38.00
DP Discs
100.00
Disc
Calibration Number
175.00
Range
17.00
8.00
DP 30-050940
DP 30-250940
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Recipe Setup for Extrusion:
1. Turn power switch to ON position.
2. Press
3. Press
Input to display # 1, “Additive %”. Using arrow keys, set additive ratio.
Input to display # 2, “Throughput of extruder”. Using arrow keys, set the
total extruder throughput in g/min or lb/min.
4. Press
Input to display # 3, “Extruder screw speed”. Using arrow keys, set the
extruder screw speed RPM expected during production.
NOTE: For Extrusion - Constant operation, the above step will be skipped.
5. Press Input to display # 4, “Calibration weight for additive”. Enter the appropriate value
from the range table on page 9 and proceed to calibration mode below for calibration
of additive material.
Calibration:
1. Press
“Calibration” button to start this procedure. Display will show - - - -
2. Place the plastic calibration cup on the scale and tare so that the weight of the cup
(approx. 24 grams) is not calculated in the calibration procedure.
3. Remove cover of the calibration box, secured by two 5 mm Allen screws, under the
dosing disc assembly and insert plastic cup provided in top of dosing hopper.
4. Press
“Run” and the dosing disc turns 1/4 turn. This fills all pockets of dosing
disc. Dump the dosed material back into the dosing hopper without weighing and
replace plastic cup in calibration box.
5. Press
“Run” and the dosing disc turns 1 complete revolution. Remove the
calibration cup with the material and place on the gram scale. Enter the weight on the
scale into the controller
cup.
using the arrow keys. Empty and replace calibration
6. Repeat step # 5 four more times, each time entering the new weight from the scale
into the controller using the arrow keys. Sometimes the values won’t change, or
sometimes they may only change by a few tenths of a gram. The controller keeps a
running average of all calibration weights entered.
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7. After all five samples have been completed; press “run” once more and this will save
the calibration weight of the material to the recipe. The calibration light will go out and
the screen will now show the total amount of additive dosed. The Digital Dosing feeder
is now ready to begin operation.
8. Please refer to “Operation Manual” for all supplementary information regarding
general operation, cleaning/maintenance, and troubleshooting.
9. Make sure that there is a virgin material supply setup to begin processing. If you do
not have a loader or hopper for the virgin material, or if any of the above procedures
did not work properly, please contact ACS Technical Support @ (800) 423-3183
(8 AM - 5 PM) CST.
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Basic Input Parameters for Digital Dosing Feeder with
Injection Software (P1._ _ - Older units) or (P2._ _ - newer units)
Hold Stop and Input buttons until “7” flashes
- Enter the input number for the specific motor from the table below.
- This value sets the impulses of the encoder.
Manufacturer Motor Color RPM Input Number
Bauer
Bauer
Bauer
Bison
Bison
Bison
Bison
Blue
Blue
Blue
Black
Black
Black
Black
6.4
11.5
35.5
2
6
12
11739
6600
2135
65000
25200
14103
4387
38
Press Input button
- When “8” flashes, enter 0.7 for Blue Bauer motor.
- Or, enter 0.5 for the black Bison or Colorblend S motor.
- This value sets the nominal current for the motor.
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Press Input button
-When “9” flashes, enter the configuration value.
- Please see the list: “Determining Configuration Value” for more information.
Press Input button
- When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
- If any another motor is intended for use, enter 0.
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Press Input button
- When “11” flashes, enter 50
- This value is the minimum input frequency.
Press Input button
− When “12” flashes, enter 5.56
− This value is the span factor.
Press Input button
− When “13” flashes, enter the communication address.
− If Euromap17 is not intended to for use, enter 0.
− This value is the communication address. Only enter a value here if Euromap17
report is in use.
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Press Input button
− When “14” flashes, enter 220
− This value is for the material contents of the mixing hopper.
− Only in case of mounting on a micro mixing-hopper.
Press Stop to exit parameters, “18” will flash, then it automatically returns to the totalizer
screen
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Basic Input Parameters for Colorblend C-150 with
Extrusion Software (E1._ _ - Older units) or (E2._ _ - newer units)
Hold Stop and Input buttons until “7” flashes
- Enter the input number for the specific motor from the table below.
- This value sets the impulses of the encoder.
Manufacturer Motor Color RPM Input Number
Bauer
Bauer
Bauer
Blue
Blue
Blue
6.4
11.5
35.5
11739
6600
2135
Bison
Bison
Bison
Bison
Black
Black
Black
Black
2
6
12
38
65000
25200
14103
4387
Press Input button
- When “8” flashes, enter 0.7 for blue Bauer motor.
- Or, enter 0.5 for the black Bison or Colorblend S motor.
- This value sets the nominal current for the motor.
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Press Input button
- When “9” flashes, enter the configuration value.
- Please see the list: “Determining Configuration Value” for more information.
Press Input button
- When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
- If any another motor is intended for use, enter 0.
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Press Input button
- When “11” flashes, enter 50
- This value is the minimum input frequency.
Press Input button
When “12” flashes, enter 10
This value is the span factor.
−
−
Press Input button
− When “13” flashes, enter the communication address.
− If Euromap17 is not intended to for use, enter 0.
− This value is the communication address. Only enter a value here if Euromap17
report is in use.
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Press Input button
- When “14” flashes, enter 220
- This value is for the material content of the mixing hopper.
- Only in case of mounting on a micro mixing-hopper.
Press Stop to exit parameters, “18” will flash, then it automatically returns to the totalizer
screen.
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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. If an adapter is
necessary, it must be designed so that there are no edges where material can be
trapped. The adapter must be smooth to promote even material flow. Consult factory
for any special requirements.
2. Optimum mounting of the Digital Dosing feeder is shown in Figure 4, with the additive
being dosed on the first screw flights.
3. The controller can be mounted on either side of the blender base to optimize operator
interface. An optional remote mounting kit for the controller is available from the
manufacturer to relocate the controller closer to the operator. The control unit must not
be exposed to extreme heat (maximum temperature 45°C or 115°F) or excessive
moisture.
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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. Electrical Diagram
• Extrusion - Constant: Wire the cycle/run slave cable (thin two- conductor cable) to
a set of DRY (NO VOLTAGE) contacts that CLOSE when the screw rotates. See
Figure 5 for electrical diagram.
• Extrusion - Proportional: Wire the cycle/run slave cable to the extruder signal
output that is proportional to the extruder speed. The signal output can be one of
the following: 0-10 VDC or 0-20 mA. Please refer to the labels on the cycle/run
slave cable for the correct input to avoid damaging the controller. Digital Dosing
Additive Feeder should be configured from the factory for each specific input.
See Figure 6 for analog inputs.
NOTE: Voltage from Extruder needs to be isolated. Consult factory for other signal
requirements. External signal converter may be required.
NOTE: Zero input corresponds to zero screw speed and no additive dosing.
Maximum input corresponds to maximum screw speed.
NOTE: If a 0-10 kHz frequency input is used, it must be a square wave width and
an amplitude of 12 VDC. The shape of the signal is important, especially
above 7,000 Hz.
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J12-4
J12-3
_
+
0-10 VDC or 0-20 mA
Extruder output
Digital Dosing controller
(diagram of analog inputs)
Figure 6. Analog Inputs
5. Make sure the unit is turned OFF before plugging it in. The switch toward the rear of
the controller unit should be in the OFF, or “O” position. Standard operation voltage is
110 or 220 VAC, 50/60 Hz, single-phase power. Special voltages are available, refer
to voltage label on the feeder to determine the correct operating voltage.
Extruder Follower Interface Signal Converter
Isolating power sources and sensor signals is the most effective method for eliminating
undesirable ground loop currents and induced electrical noise.
To determine the correct signal convert to use:
o Define whether a current (mA) or voltage (dc) signal from the extruder is
available to utilize.
o The range should be either be 0-20 mA or 0-10 VDC, respectively.
o The controller has no specific requirement other than the signal being isolated
and proportional to the speed of the extruder.
Signal Converter with AC Power Supply
Vendor:
Order Designation: MCR-FL-C-UI-UI-DCI-24/230
Supply Voltage: 20V to 253V AC/DC
Phoenix Contact
Input 4-20 mA, 0-10 VDC (Quantity: 1)
Output 0-20 mA, 0-10 VDC (Quantity: 1)
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Signal Converter with DC Power Supply
This module requires a separate 24 VDC power supply.
Vendor:
Order Designation: MCR-FL-C-UI-2UI-DCI-NC
Supply Voltage: 20 to 30V DC
Phoenix Contact
Input 4-20 mA, 0-10V (Quantity: 1)
Output 0-20 mA, 0-10V (Quantity: 2)
24 VDC Mini Power Supply
A Phoenix Contact power supply for the Phoenix Contact signal conditioner listed above.
Vendor: Phoenix Contact
Order Designation: MINI-PS-100-240AC/24DC/1
Please note that the data given here has been taken from Phoenix Contact's online catalog.
For comprehensive information and data, please refer to the user documentation at
3.2 Initial Operation
The control system is factory-programmed. Nevertheless, specific values need to be
predefined or checked prior to operation (basic parameter settings). The input values will be
saved and will still be available if the unit is switched off, or a power failure occurs. Please
refer to Appendix B for these values. Extrusion operations require a “span factor” to be
entered into the basic settings. Please refer to Appendix B.
Prior to putting your new Digital Dosing Additive Feeder on-line:
• You must enter a recipe and calibrate the feeder.
• 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, recipes can be saved for later recall (10 maximum).
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• This section will show how to calibrate the unit, bring the unit on line, enter a
recipe, and store and recall recipes.
3.3 Injection Molding
During each molding cycle the Digital Dosing unit doses the correct amount of additive evenly
throughout the screw recovery cycle. The Digital Dosing unit determines the correct amount
of additive from the recipe and automatically adjusts the duration and speed of dosing by
measuring the molding machine screw recovery time each cycle.
Recipe Input - Injection Molding
To enter a recipe for injection molding, the following process data is required:
• Percentage of additive
• Total shot weight in grams (includes parts and runner system)
• Screw recovery time of the machine in seconds
• Calibration weight in grams
• Step 1:
• Press Input
once.
flashes.
• The LED symbol
• “1” will quickly flash on the display, before a number in the format xxx.xx
comes up on 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 by larger increments.)
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Step 2:
• Press Input
again.
• The symbols “g,” or “lb”, “min” and the screw symbol flash.
• After the “2”quickly flashes on the display, a number in the format xx.xxx will
come up on the display.
• Enter the shot weight using the arrow keys. The range of values that can be
entered is 001.0 to 6500 grams (0.01 to 14.30 pounds).
Step 3:
“3” = screw recovery time in seconds
• Press Input
a third time.
• The screw and “s” symbols flash.
• After “3” flashes quickly on the display, a number in the format xxx.xx will come
up on the display.
• Enter the screw recovery time in seconds. This time represents the amount of
time the molding machine screw is in recovery. This value is an estimate.
The Digital Dosing unit measures the actual recovery time and automatically
updates this value during operation. NOTE: The range of values that can be
entered in this field is 2.00 to 99.99 seconds.
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Step 4:
“ 4 “ = calibration weight in grams or pounds
• Press Input
a fourth time.
• The symbols “g” or “lb”and flash.
• After “4” quickly flashes on the screen, a number in the format xxxx.x will come
up on the display.
• Enter the calibration weight in grams. If the calibration weight is unknown,
enter “valve” from (section 5.7 knowing you Disc size) to obtain a starting
weight.
•
The range of values that can be entered in this field is 00.0 to 400.0.
Please note: Parameters 5 and 6 will only be displayed when a mixer and or a
printer is configured.
Step 5:
• Press
again and the symbol “s” will light up and the number “5” will be
displayed if you have a blending unit and have invoked this option.
• After “5” flashes on the display, a number in the format xxx.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.
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Step 6:
• Pressing
again, will activate the printing option if it is available.
• After the “6” flashes on the screen, a number in the format xxx.xx will come up
on the display.
• By using the arrow keys, you can choose your printer parameters.
Step 7:
1. Pressing
again will first display the number “18” and then will display the total
throughput in kilograms (totalizer).
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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. Place the Digital Dosing feeder into operation by pressing the Run key (
).
The green LED will light when the unit is ready to dose.
or
Start the molding machine. The Digital Dosing feeder will not dose material until the molding
machine screw recovers. If the unit is installed properly, the process machine symbol
will 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.
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• 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. To change the recipe, the unit must be taken
off line by pressing the stop key. The run LED will then go out.
NOTE: See Appendix A, Troubleshooting, for information on problems or errors
encountered and their resolution.
3.4 Extrusion – Constant (Standard)
In Extrusion Constant operation, the Digital Dosing unit doses material at a constant rate that
does not change with extruder speed. The dosing process begins at the startup of the
extruder. How close the actual extruder speed is to the input recipe will determine the
accuracy of the blend. If the process requires the additive to be dosed in proportion to
the process speed, then the Digital Dosing unit must be configured for Extrusion
Proportional operation (go to Section 3.5).
Recipe Input – Extrusion - Constant
To enter a recipe for Extrusion Constant, the following process data is required:
• Percentage of additive
• Total throughput rate of the extruder during production
• Calibration weight in grams
• Step 1:
• Press
once.
• The
symbol will flash.
• After “1” flashes on the screen, a number in the format xxx.xx will come up on
the display.
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• 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.
•
The symbols “g,” or “lb”, “min”, and
flash.
• After “2” flashes quickly on the display, a number in the format xxx.xx will come up on
the display.
• Enter the total extruder throughput in grams per minute or pounds per minute. The
range of values that can be entered is 001.0 to 6500 grams per minute (00.01 to 14.30
lb/m).
Extrusion Constant, parameter “3” is skipped.
Step 3:
“ 4 “ = calibration weight in grams or pounds
• Press
a third time.
• The machine displays a flashing , “g” or “lb” and a number “4”flashes on the display
• After the “4” flashes on the display, a number in the format xxxx.x will come up.
• Enter the calibration weight in grams. If the calibration weight is unknown, enter
the appropriate “value” from Section 2, based on your disc size, to obtain a
starting weight.
• The range of values that can be entered in this field is 00.00 to 400.0.
Note: Parameters 5 and 6 will only be displayed when a mixer and
or a printer is configured.
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Step 4:
• Press
again and the symbol “s” will light up and the number “5” will be
displayed if you have a blending unit and have invoked this option.
• After “5” flashes on the display, a number in the format xxx.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.
Step 5:
• Press
again. This will activate the printing option if it is available and the number
“6” will be displayed.
• After the “6” flashes on the screen, a number in the format xxx.xx will come up on the
display.
• By using the arrow keys, you can choose your printer parameters. If you have not
activated this option, skip to the next step.
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Step 6:
6. Press
again.
7. The number “18” will be displayed before the total throughput in kg is displayed.
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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
display is reset to “00.00.”
continuously for 5 seconds until the
3. Place the Digital Dosing unit into operation by pressing
. The green LED will
light when the unit is ready to dose, but the Digital Dosing unit will not feed until
the extruder begins operation.
4. 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 unit is dosing material.
5. To stop the dosing process while the extruder is operating, press
. The
Digital Dosing unit will automatically stop dosing when the extruder stops.
6. While the unit is dosing, depending on software revision, the current recipe can be
viewed but not modified, by pressing
. In some software versions, the
percent additive can be changed while the unit is dosing.
NOTE: See Appendix A, Troubleshooting, for information on problems or errors
encountered and their resolution.
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3.5 Extrusion – Proportional (Extruder Follower Option)
Recipe Input – Extrusion Proportional
To enter a recipe for Extrusion Proportional, the following process data is required:
• Percentage of additive
• Expected throughput of the extruder during production
• Extruder screw speed during production
• Calibration weight in grams
Step 1:
• Press the Input key,
• The symbol flashes.
, once.
• After “1” flashes quickly on the display, a number in the format xxx.xx will come
up on 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.
• The machine displays a flashing “g” or “lb”, a flashing “min” and
.
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• After “2” flashes quickly on the display, a number in the format xxx.xx will come
up on the display.
• Enter the expected extruder throughput during production in grams per minute
or pounds per minute. The range of values that can be entered is 001.0 to
6500 grams per minute (00.01 to 14.30 lb/m).
Step 3:
• Press
a third time.
• The machine displays a flashing screw
.
• After “3” flashes quickly on the display, a number in the format xxx.xx will come
up on the display.
• Enter the extruder screw speed (rpm) corresponding to the throughput entered
in step 2.
Step 4:
“ 4 “ = calibration weight in grams or pounds
• Press
a fourth time.
• The machine displays a flashing and “g”.
• After “4” flashes quickly on the screen, a number in the format xxx.xx will come up
on the display.
• Enter the calibration weight in grams. If the calibration weight is unknown,
enter the appropriate “value” from Section 2, based on your disc size, to
obtain a starting weight.
•
Upon completion of the calibration procedure, the calibration weight will
automatically be updated into the recipe. The range of values that can be
entered in this field is 00.00 to 400.0.
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Please note: Parameters 5 and 6 will only be displayed when a mixer and or a
printer is configured.
Step 5:
• Press
again and the symbol “s” will light up and the number “5” will be
displayed if you have a blending unit and have invoked this option.
• 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.
Step 6:
• Press
again. This will activate the printing option if it is available and the number
“6” will be displayed.
• After the “6” flashes on the screen, a number in the format xxx.xx will come up on the
display.
• By using the arrow keys, you can choose your printer parameters. If you have not
activated this option, skip to the next step.
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Step 7:
• Press
a fifth time to return to the totalizer.
Operation – Extrusion – Proportional (Extruder Follower Option)
; Ensure that the unit is properly installed (Section 3.1)
; A recipe is entered (“Recipe Input-Extrusion Proportional” Section )
; The feeder is calibrated (Section 3.6), before attempting to begin operations.
1. If desired, clear the totalizer by pressing
the display is reset to “00.00.”
continuously for 5 seconds until
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. To stop the dosing process while the extruder is operating, press
. The
Digital Dosing unit will automatically stop dosing when the extruder stops.
5. While the unit is dosing, depending on software revision, the current recipe can
be viewed but not modified, by pressing
. In some software versions, the
percent additive can be changed while the unit is dosing. The actual extruder
screw speed will be displayed in the third recipe register.
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3.6 Calibration
All feeders must be calibrated before any blending recipes can run using the Digital Dosing
additive feeder.
NOTE: The calibration weight (metered material weight for one revolution of the
dosing disc) must be determined separately for each material to be dosed
since calibration weight differs from material to material.
The following equipment is needed for calculating the calibration weight:
• Scale with a minimum accuracy of 0.01 grams
• The weighing container which is included in the equipment delivery
Follow these procedures:
1. Remove one of the square covers and insert the calibration container provided.
2. Fill the dosing hopper with a minimum of six (6) inches of material.
3. Note weight of weighing container (= tare weight) or tare scale to zero
NOTE: The Digital Dosing station may only be operated if all sample chutes are in
place or a collecting bin is in the calibration box.
Determining the Calibration Weight
Step 1:
• 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.
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• 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.
• Replace container in calibration box (or under material outlet tube)
Step 3:
• Press
to take a sample for weighing.
• 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.
• The value is an average of all the weights entered. No calculations are
required. It can happen that the calculated speed is either too high or low
causing alarm A0009. Check the recipe and settings and modify if
necessary.
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Step 6:
After the fifth calibration sample press “ RUN “ the controller will
automatically finish the calibration cycle and be ready to run. The following are
methods used to interrupt the calibration cycle.
• 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.
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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:
• Press the Recipe Storage/Recall key (
). A two-digit number (01 through 10) will
appear on the screen. This is the recipe I.D. number.
Step 2:
• Use the Arrow keys
to select the desired recipe number.
NOTE: A new recipe stored under the ID number of an existing recipe will overwrite
the existing recipe number without warning.
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Step 3:
or
• Press and hold the button
until the totalizer display returns to the screen.
• The recipe is now stored under the selected ID number.
Recipe Recall
Step 1:
or
• Press the stop button to stop any current applications.
Step 2:
• Press the Storage/Recall key (
) once.
• A two-digit recipe ID number will appear on screen.
Step 3:
• Use the Arrow Keys
to select the desired recipe number.
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Step 4:
• Press and hold
until the totalizer appears on the screen.
• The recipe is now active and can be run or edited.
NOTE: The recalled recipe now becomes the active recipe.
4.2 Clearing the 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.
• See Appendix A to learn how to change the unit of measure.
4.3 Acknowledging Alarms
• When an alarm occurs, the Alarm symbol
process stops.
flashes red and the dosing
• If the Digital Dosing is equipped with an audible alarm or flashing light, it will
also be activated.
• Alarms are acknowledged by pressing
.
• The alarm will also initiate an error code.
• See Appendix A for Troubleshooting suggestions for various alarms.
• The alarm condition must be corrected prior to beginning operation again.
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4.4 Optional Equipment, Level Switches and Communications
Options
Optional equipment for the Digital Dosing Additive Feeder includes:
Alarms
Several alarm options are available for the Digital Dosing feeder. The standard unit comes
with a flashing alarm symbol
on the faceplate. Options include both audible horns and
flashing lights. An optional no voltage alarm relay can be connected to the user’s central
alarm system.
Level switches (probes)
To adjust the level switches:
1. Turn the controller ON.
2. Fill the dosing station until the level sensor is one-third covered.
3. Remove the small plastic screw (M3) on the back of the level sensor (see
Figure 7).
LED Yellow (Station)
on: Station Filled
LED Green (Level Probe)
on: Power Supply Available
off: Power Supply Not Available
off: Station Emptied
npn: Normally Closed
pnp: Normally Open
npn: Normally Open
pnp: Normally Closed
1
0
Blind Lid
Protective Screw
Trim-pot with
Plastic Screw M3
Cable
Level Probe
Figure 7. Level Sensor Screw
4. Turn the trim-pot until the yellow control lamp just switches off.
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NOTE: Turning the trim-pot to the left decreases the switching sensitivity; turning it
to the right increases the switching sensitivity.
5. Fill the dosing station until the level probe is two-thirds covered. The yellow
control lamp should now switch on again. If not, repeat Step 4.
6. Reinstall the plastic screw (M3).
NOTE: The sliding switch under the cover must be set on “0”.
Communication Protocol Interfaces
The Digital Dosing unit can be controlled remotely through the EUROMAP E17 or MODBUS
RTU protocol. Contact Sales and Service concerning this option at 810.720.7300.
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Section 5: Maintenance
5.1 Maintenance Intervals
Check warning signs on equipment for good legibility
and completeness.
Daily:
Check function of the “On/Off” Switch.
Weekly:
Check shear plate in “DD” dosing station, and wiper in
“DT” dosing station.
Every 3
months:
Check that all electrical and mechanical connections
are tight.
Every 6
months:
Check adjustment of the level probes (optional).
Check dosing disc in dosing station DD/DT.
Clean the dosing station.
Annually:
Each time
after
material
Is changed:
Check shear plate or wiper.
Check dosing disc.
5.2 Removing the Shear plate (DD feeder only)
Removing the shear plate
1. Empty the dosing
station.
2. Open the profile clamp
(B) on the dosing
hopper.
3. Remove the dosing
hopper from the dosing
unit.
4. Open the safety screws
at the toggle-type
fasteners.
5. Open the toggle-type fasteners on the dosing motor.
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6. Remove the dosing unit from the dosing motor.
7. Remove the cover from the connecting piece (D).
8. Loosen the two screws (C) on the underside of the dosing unit housing (E).
9. Remove the shear plate (A).
Installing the shear plate
1. Place the new shear plate in the dosing unit housing.
2. Ensure that the shear plate is positioned correctly.
3. Screw the shear plate in place by means of 2 hexagon socket screws (M5 x 16).
4. Turn the dosing disc to check for smooth movement.
5. Mount the cover on the connecting piece.
6. Position the dosing unit on the dosing motor (note guide pins).
7. Close the toggle-type fasteners on the dosing motor.
8. Mount the safety screws.
9. Position the dosing hopper on the dosing unit.
10. Mount the profile clamp.
11. Mount the screw at the profile clamp.
5.3 Cleaning the “DD” Digital Dosing Station
Dismantling the Dosing Station
1. Empty the dosing station.
2. Switch the control unit off by means
of the on/off switch.
3. Disconnect from main voltage.
4. Open the profile clamp on the
dosing hopper.
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5. Remove the dosing hopper from the dosing unit.
6. Dismantle the dosing unit and remove the shear plate (D).
7. Loosen the two hexagon socket screws (B, M6 x 30) on the 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 shear plate using a
cotton cloth.
11.Clean the dosing hopper and
the dosing disc in soapy water.
12.The dosing unit housing may
also be cleaned with soapy
water.
13.Ensure that soapy water does
not enter ball bearings.
14.Dry all parts thoroughly.
Installing the Dosing Station
1. Place the dosing disc in the dosing unit housing.
2. Remove the screw (M6 x 60).
3. Screw the dosing disc in place by means of 2 hexagon socket screws (M6 x 30).
4. Mount the center hexagon screw (M6 x 12).
5. Install the shear plate and then the dosing unit.
6. Turn the dosing disc to check for smooth movement.
7. Position the dosing hopper on the dosing unit.
8. Tighten the profile clamp.
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5.4 Changing the Dosing Disc in the “DT” Digital 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 shear plate.
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. Change and place the dosing disc in the dosing unit housing.
2. Remove the screw (M6 x 60).
3. Screw the dosing disc in place by means of 2 hexagon socket screws (M6 x
30).
4. Mount the center hexagon socket screw (M6 x 12).
5. Install the shear plate and then the dosing unit.
6. Turn the dosing disc to check for smooth movement.
7. Position the dosing hopper on the dosing unit.
8. Tighten the profile clamp.
See Appendix D: Spare Parts List on page 61 for disc part numbers.
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Installing Different Types of Dosing Discs
Dosing discs of the same type, and thickness (72 pocket), may be exchanged for each other
without any problems. If dosing discs with a different compartment number or thickness are
installed, this has to be entered in the control system!
DD Discs
Disc
Calibration Number of
Number
1.75
pockets
72
DD 30-030672
DD 30-051040
DD 30-051725
DD 30-051818
5.00
40
8.00
25
15.00
18
1. Enter the (preliminary) calibration value of the newly installed dosing disc
2. Execute “calibration” to determine the final calibration value.
5.5 Removing / Replacing the Wiper in the DT Dosing Station
1. Empty the dosing station.
2. Open the profile clamp (C) of the
dosing container.
3. Remove the profile clamp (C)
4. Remove the dosing container (B)
along with the dosing hopper (A).
5. Loosen the 3 plastic screws on
the wiper.
6. Remove the wiper and holding
plate.
7. Install the new wiper along with
the holding plate.
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8. Tighten down the 3 plastic screws. Make sure that the wiper is fitted parallel to the
dosing plate (Use only plastic screws to avoid damage to the extruder or
molding machine screw should the mounting screws ever come loose.)
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. Open the safety screws at the toggle-
type fasteners.
8. Open the toggle-type fasteners.
9. Remove the dosing housing (D) from
the mixing hopper.
10. Clean the dosing housing (D) with a paintbrush.
11. Clean the dosing container (B) and the dosing hopper (A) in soapy water.
12. Dry all parts thoroughly.
13. Mount the dosing housing onto the dosing motor.
14. Observe that the guide pins are locked into position.
15. Close the toggle-type fasteners.
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16. Mount the safety screws.
17. Install the dosing container along with the dosing hopper on the dosing housing
(pay attention to the guide pins).
18. Mount the profile clamp.
19. Mount the screw at the profile clamp and tighten.
5.7 Exchangeable Stations
Dosing discs of the same type may be exchanged for each other without any problems. If
dosing discs with a different compartment number are installed, this has to be entered in the
control system.
1. Enter the (preliminary) calibration value of the freshly installed dosing disc
DT Discs
Disc
Calibration Number of
Number
32.00
Pockets
DT 30-101820
DT 30-102025
DT 30-203012
DT 30-204010
20
25
12
10
38.00
100.00
175.00
DP Discs
Disc
Calibration Number
Disc
Number
of
Pockets
40
Thickness
DP 30-050940
17.00
8.00
0.5 mm
2.5 mm
DP 30-250940
40
2. Execute “calibration” to determine the final calibration value.
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5.8 Replacing Fuses
1. Stop the continuous operation.
2. Wait until the dosing unit has stopped.
3. Switch off the device with the on/off switch.
4. Cut off the voltage supply.
5. Wait at least one minute before starting to work at the unit or controller.
6. Never try to repair a
defective fuse.
7. Open the screws
(A) and remove the
lid (B).
8. Remove the blind
lid (C) and open the
screws.
9. Move the lid (D)
aside.
10. Remove the defective fuse from the fuse carrier.
11. Install the new fuse (while observing the value).
12. Mount the lid (D).
13. Fasten the screws and the blind lids (C).
14. Mount the lid (B).
15. Mount the screws (A).
See Appendix D for fuse part numbers.
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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 3.1) and Extruder - Constant
Applications (Section 3.1). For Extrusion - Proportional Applications (Extruder
Follower OPTION) see Section 3.5.
• Ensure the correct Configuration Codes have been entered to configure the Digital
Dosing unit for the process and installation, see Section 2.
A.2 Malfunctions - Error Codes
When a malfunction or error occurs, the controller displays the Alarm symbol
and an
error code. The code consists of an “A,” followed by an error number. The control unit will
not operate until the malfunction or error has been corrected. To acknowledge and clear the
alarm, press the Stop key (
dosing operations.
). Once the malfunction is corrected, press
to begin
NOTE: Stop
will not correct a malfunction or error.
Following is a table with the error codes, possible reasons for each code, and solutions to the
problems presented.
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ERROR CODES
Code
A001
A002
Definition
Strap “safety switch” is missing.
The nominal current of the dosing motor Dosing motor defective or jammed.
Possible Reason/Solution
Manufacturer Service.
(=100%, see name plate) is being
exceeded for more than 2 seconds by
30% or for a maximum of 0.5 seconds
by 80%.
Check the dosing motor and exchange it
if necessary. Check whether the dosing
disc is jammed by material and remove
the material if necessary.
A003
The nominal current of the dosing motor Dosing motor defective or jammed.
(=100%, see name plate) is being
exceeded for more than one minute.
Check the dosing motor and exchange it
if necessary. Check whether the dosing
disc is jammed by material and remove
the material if necessary.
A004
A005
Excess temperature. The temperature
within the controller housing is > 85°C
Check whether the cooling plate at the
back of the controller is sufficiently
cooled down. Use fan if necessary.
The encoder (pulse generator) does not If dosing motor does not turn, check
emit any pulses for approximately 2
seconds.
whether the dosing disc is jammed by
material and remove the material if
necessary. If disc is free, check the
dosing motor, exchange if necessary. If
motor operates, but alarm persists,
check speed encoder output. Replace as
necessary.
A006
For approximately 4 seconds, there is a Defect at the dosing motor. Check
deviation of the motor speed of more
than 20% from the nominal rotational
speed.
dosing motor, exchange if necessary.
Check whether the dosing disc is
jammed by material and remove the
material if necessary. Power supply part
or control out of order. Manufacturer
Service.
A007
A008
A009
Dosing motor stops or doesn’t work.
Brake at the dosing motor out of order.
Control system out of order.
Manufacturer service.
The screw retract time of the processing The unit cannot be operated in
machine is shorter than 0.1 seconds.
combination with this processing
machine.
Check basic parameter settings and
recipe, modify if necessary. May require
changing to different sized dosing disc.
The calculated speed of the motor is
either too high or too low.
A0010 The feed station is not able to meter the Check basic parameter setting and
desired recipe.
recipe, modify if necessary. May require
changing to different sized dosing disc.
Refill Material.
A0011 The raw material probe is not covered
A0012 The additive probe is not covered.
Refill material.
A0014 Power failure interrupted run cycle.
A0015 EEPROM data loss, EEPROM not
programmed.
Clear alarm after power restored.
Manufacturer Service.
A0016 No communication between HOST and Check cable fittings. Manufacturer
unit.
Service.
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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.4 Recipe Formulas
The following formulas can be used to determine if a recipe is appropriate or possible.
Injection Molding
For injection molding applications, compute the dosing disc speed and total number of disc
revolutions using the following formulas. Recipe limitations are listed in the table following
the equations.
(Shot Weight - g) x (Additive - %) x 0.6
Disc RPM =
(Disc Calibration Weight - g) x (Recovery Time - s)
(Shot Weight - g) x (Additive - %) x 0.01
Disc Revolutions per Shot =
(Disc Calibration Weight - g)
Recipe Limitations for Injection Molding
Motor Assembly Speed (rpm)
Maximum
Number of Disc Revolutions
Speed (rpm)
11.5
11.5
35.5
4.6
14.8
35.5
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Extrusion
For extrusion applications compute the dosing disc speed using the following formula.
Recipe limitations are listed in the table following the recipe.
( Additive - %) x (Total Extruder Throughput - lb / hr)
Disc RPM =
13.22 x (Disc Calibration Weight - g)
Recipe Limitations Extrusion
Motor Assembly Speed (RPM)
Maximum
Speed (RPM)
11.5
11.5
35.5
35.5
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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 12 VDC square wave)
• 0 - 10 VDC signal
• 0 - 20 mA current 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. Record the
data.
Max. input frequency = __________ Hz
If a voltage signal is available (0 - 10 VDC) calculate the frequency output of the extruder for
the lower / upper working area using the formula:
Frequency [Hz] = Input voltage [V] x 10000 [Hz]
10 [V]
Note the data:
Min. input frequency = __________ Hz
Max. input frequency = __________ Hz
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:
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Frequency [Hz] = Input current [mA] x 10000 [Hz]
20 [mA]
Note the data:
Min. input frequency = __________ Hz
Max. input frequency = __________ Hz
Calculate the span factor using the formula:
Span factor [Hz / rpm] =
Frequency [Hz]____________
Rotational speed of the extruder [rpm]x 10
Note the data:
Span factor = __________
Determining the Configuration Value
Extrusion (Constant or Proportional):
Mark the functions required. Use the numerical value indicated and insert it in the empty field
if applicable. Total the figures for configuration value.
Optional raw material level probe installed . . ................ . . . . . . . . . . . . . . . . . ..1
Optional additive level probe installed . . . . . . . . . . . . . ................ . . . . . . . . . ..2
Optional blending unit installed . . . . . . . . . . . . . . . . . . . . . . . . . . ............... . .. 8
Totalizer displayed in lb (kg default) . . . . . . . . . . . . . . . . . . . . . . . . ................ 16
Extruder throughput (1 kg-6.5 Kg/min) . . . . . .(2.2 lbs/min-14.3 lbs/min) ……..0
Extruder throughput (10 kg-65 kg/min)……….(22 lbs/min-143 lbs/min). . . . . 32
___
___
___
___
___
___
Extruder throughput (0.1 kg-0.65 Kg/min) . . .(0.22 lbs/min-1.43 lbs/min)…....128 ___
(NOTE: the throughput selections determine placement of the decimal point on the display)
External run/stop signal controls dosing . . . . . . . . . . . . . . . . . . . . .............. . 64
Mounting on Micro mixing hopper . . . . . . . . . . . . . . . . . . . . . . . . . ............... . 256 . ___
Alarm output is switched in case of power failure . . . . . . . . . . .............. 512 ___
___
Extrusion proportional . . . (extruder follower). . . . . . . . . . . . . . . . ............ . 1024 _____
Extrusion Constant ………………….……………………………………........…3072______
Printer available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........16348 ____
Configuration value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …............ _____
Example:
• Level probes: raw material and additive probes installed
59
Digital Dosing Units
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• Throughput: 8000 g/min
• Totalizer displayed in lbs
• Extrusion mode
Raw material probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Additive probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Totalizer displayed in lb. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .16
1
2
__
16
Extruder throughput (1 kg-6.5 Kg/min) . . . . . .(2.2 lbs/min-14.3 lbs/min) …….0
___
32
Extruder throughput (10 kg-65 kg/min)……….(22 lbs/min-143 lbs/min). . . . . 32
Extruder throughput (0.1 kg-0.65 Kg/min) . . .(0.22 lbs/min-1.43 lbs/min)….128 ___
External run/stop signal controls dosing . . . . . . . . . . . . . . . . . . . . 64
___
___
Mounting on a Micro mixing-hopper. .. . . . . . . . . . . . . . . . . . . . . . 256
Alarm output switched in case of power failure . . . . . . . . . . . . . . .512 ___
Extrusion mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024 1024
Printer available . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 16348 ____
Configuration value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075
Injection Molding:
Mark the functions required. Use the numerical value indicated and insert it in the empty field
if applicable. Total the figures for configuration value.
Optional raw material level probe installed . . . . . . . . . . . . . . . . . . . . 1
Optional additive level probe installed . . . . . . . . . . . . . . . . . . . . . . . .2
___
___
60
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Optional blending (mixing) unit installed . . . . . . . . . . . . . . . . . . . . . .8
Totalizer displayed in lb (kg default) . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shot weight (1 kg-6.5 Kg) ……………. . . . . .(2.2 lbs-14.3 lbs) …….0
Shot weight (10 kg-65 kg)……………………..(22 lbs-143 lbs). . . . . 32
___
___
___
___
Shot weight (0.1 kg-0.65 Kg) . ……………… .(0.22 lbs-1.43 lbs)….128 ___
(NOTE: The shot weight selections above determine placement of the decimal point
on the display)
External run/stop signal controls dosing . . . . . . . . . . . . . . . . . . . . . . 64
Mounting on Micro mixing hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
___
___
___
Alarm output is switched in case of power failure . . . . . . . . . . .
512
Printer available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16348 ____
Configuration value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
_____
Example:
• Level probes: additive probe installed
• Shot weight: 8 kg
• Totalizer displayed in lb
Raw material probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
__
61
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Additive probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blending unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Totalizer displayed in lb. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .16
Shot weight up to 6.5 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
or
2
__
16
Shot weight 6.5 to 65 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
External run/stop signal controls dosing . . . . . . . . . . . . . . . . . . . . 64
Mounting on a Micro mixing-hopper. .. . . . . . . . . . . . . . . . . . . . . . 256
32
___
___
Alarm output switched in case of power failure . . . . . . . . . . . . . . .512 ___
Printer available . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 16348 ____
Configuration value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _50_
62
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Appendix C: Dosing factors, equipment drawings and part numbers
Disc Dosing Factor Table 1: Disc Guide
Disc
Disc
Minimum/
Maximum
Disc
Weight Per Disc Min. Throughput
Max.
Weight Per
Disc
Revolution
(44 lbs./cu. ft.)
Min.
Max.
Nomenclature
Used in the
Controller
Revolution
(35 lbs/cu. ft.)
with 100%
Continuous
Running
Throughput
with 100%
Continuous
Running
Throughput
with 100%
Continuous
Running
Throughput
with 100%
Continuous
Running
Revolution
(35 lbs./cu. ft.)
(35 lbs./cu. ft.)
(44 lbs./cu. ft.)
(44 lbs./cu. ft.)
DD30-030672
P030672
0.2 Rev./min
(6.4 RPM)
1.53 g/Rev.
0.02 g/Hole
0.04 lb/hr
0.02 kg/hr
0.10 lb/hr
0.045 kg/hr
0.19 lb/hr
1.30 lbs/hr
0.59 kg/hr
2.32 lbs/hr
1.05 kgs/hr
7.16 lbs/hr
1.95 g/rev.
0.04lb/hr
0.02 kg/h
0.12 lb/hr
0.05 kg/hr
0.26 lb/hr
1.65 lb/hr
0.75 kg/h
2.89 lb/hr
1.31 kg/hr
9.00 lb/hr
# of Holes
Diameter
Disc
0.027 g/hole
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
1.50 grams/rev
0.09 kg/hr
0.11 lb/hr
3.25 kgs/hr
3.59 lbs/hr
0.12 kg/hr
0.15 lb/hr
4.10 kg/hr
4.56 lb/hr
D30-051040
051040
0.2 Rev./min
(6.4 RPM)
4.24 g/Rev.
0.11 g/Hole
5.39g/rev.
# of Holes
Diameter
Disc
0.05 kg/hr
0.27 lb/hr
0.12 kg/hr
0.55 lb/hr
1.63 kgs/hr
6.33 lbs/hr
2.87 kgs/hr
19.80 lbs/hr
0.13 g/hole
0.07kg/h
0.35 lb/hr
0.15 kg/hr
0.70 lb/hr
2.07 kg/h
8.00 lb/hr
3.62 kg/hr
25.30 lb/hr
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
4.0 grams/rev
0.25 kg/hr
0.20 lb/hr
9.00 kgs/hr
6.23 lbs/hr
0.32 kg/hr
0.24 lb/hr
11.50 kg/hr
7.90 lb/hr
D30-051725
051725
# of Holes
Diameter
Disc
0.2 Rev./min
(6.4 RPM)
7.37 g/Rev.
0.30 g/Hole
9.38g/rev.
0.09 kg/hr
0.48 lb/hr
0.22 kg/hr
1.00 lb/hr
0.44 kg/hr
2.83 kgs/h
11.0 lbs/hr
4.99 kgs/hr
34.60 lbs/hr
15.70 kgs/hr
0.38 g/hole
0.11 kg/h
0.61 lb/hr
0.27 kg/hr
1.25 lb/hr
0.57 kg/hr
3.60 kg/h
14.0 lb/hr
6.36 kg/hr
44 lbs/hr
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
7.3 grams/rev
20 kosher
63
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DD30 051818
051818
# of Holes
Diameter
Disc
0.2 Rev./min
(6.4 RPM)
13.42 g/Rev.
0.75 g/Hole
0.35 lb/hr
0.16 kg/hr
0.85 lb/hr
0.39 kg/hr
1.76 lb/hr
11.40 lbs/hr
5.15 kgs/hr
19.60 lbs/hr
8.89 kgs/hr
63.00 lbs/hr
17.08 g/rev.
0.95 g/hole
0.44 lb/hr
0.20 kg/h
1.12 lbs/hr
0.51 kg/hr
2.20 lbs/hr
14.5 lbs/hr
6.56 kgs/h
0.5 Rev./min
(11.5 RPM)
Thickness
25.63 lbs/hr
11.62 kgs/hr
80.25 lbs/hr
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
13.5 grams/rev
0.80 kg/hr
0.75 lb/hr
28.60 kgs/hr
23.70 lbs/hr
1.00 kgs/hr
1.00 lbs/hr
36.4 kgs/hr
30.1 lbs/hr
DT30 101820
101820
0.2 Rev./min
(6.4 RPM)
28.00 g/Rev.
1.40 g/Hole
35.63 g/rev.
1.78 g/hole
# of Holes
Diameter
Disc
0.34 kg/hr
1.85 lb/hr
0.84 kg/hr
3.7 lb/hr
10.75 kgs/hr
42.23 lbs/hr
19.15 kgs/hr
131.50 lbs/hr
0.43 kg/h
2.31 lbs/hr
1.05 kgs/hr
4.70 lbs/hr
13.68 kgs/h
52.78 lbs/hr
23.94 kgs/hr
167.3 lbs/hr
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
28 grams/rev
DT30-102025
Sure-Shot disc
No Picture
1.68 kg/hr
0.87 lb/hr
59.70 kg/shr
27.94 lb/hr
2.14 kgs/hr
1.12 lbs/hr
75.9 kg/shr
35.56 lbs/hr
P102025
0.2 Rev./min
(6.4 RPM)
33.60 g/Rev.
1.3 g/Hole
42.75 g/rev.
1.71 g/hole
# of Holes
Diameter
Disc
0.40 kg/hr
2.18 lb/hr
0.99 kg/hr
12.67 kg/hr
49.77 lb/hr
22.57 kg/hr
0.50 kg/h
2.77 lbs/hr
1.26 kgs/hr
16.12 kgs/h
63.34 lbs/hr
28.72 kgs/hr
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
33 grams/rev
4.36 lb/hr
154.90 lb/hr
5.55 lbs/hr
197.25 lbs/hr
1.98 kg/hr
2.51 lb/hr
70.29 kg/hr
80.50 lbs/hr
2.52 kgs/hr
3.13 lbs/hr
89.46 kgs/hr
100.53 lbs/hr
DT30 203012
203012
0.2 Rev./min
(6.4 RPM)
95.09 g/Rev.
7.92 g/Hole
118.72 g/rev.
9.89 hole
# of Holes
Diameter
Disc
1.14 kg/hr
6.28 lb/hr
2.85 kg/hr
12.50 lb/hr
5.70 kg/hr
36.50 kgs/hr
143.28 lbs/hr
65.00 kgs/hr
446.54 lbs/hr
202.50 kgs/hr
1.42 kgs/h
7.80 lbs/hr
3.54 kgs/hr
15.65 lbs/hr
7.1 kg/shr
45.6 kgs/h
178 lbs/hr
80 kgs/hr
0.5 Rev./min
(11.5 RPM)
Thickness
1.0 Rev./min
(35.5 RPM)
557 lbs/hr
252.9 kgs/hr
Default
Calibration #
95 grams/rev
64
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DT30 204010F
204010
0.2 Rev./min
(6.4 RPM)
151.15 g/Rev.
15.12 g/Hole
4.00 lb/hr
1.80 kg/hr
10.00 lb/hr
4.53 kg/hr
20.00 lb/hr
9.00 kg/hr
128.00 lbs/hr
59.00 kgs/hr
227.74 lbs/hr
103.28 kgs/hr
705.00 lbs/hr
320.00kgs/hr
188.72 g/rev.
18.87 hole
5.0 lbs/hr
2.25 kg/h
160 lbs/hr
72.5 kgs/h
283 lbs/hr
129 kgs/hr
886 lbs/hr
402 kgs/hr
# of Holes
Diameter
Disc Thickness
0.5 Rev./min
(11.5 RPM)
12.43 lbs/hr
5.64 kgs/hr
25.00 lbs/hr
11.30 kgs/hr
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
150 grams/rev
DP30 050940
P050940
0.2 Rev./min
(6.4 RPM)
15.64 g/Rev.
0.39 g/Hole
0.41 lb/hr
0.187 kg/hr
1.00 lb/hr
0.45 kg/hr
2.00 lb/hr
13.20 lbs/hr
6.00 kgs/hr
22.62 lbs/hr
10.62 kgs/hr
73.40 lbs/hr
19.53 g/rev.
0.49 g/hole
0.51lb/hr
0.23 kg/h
0.12 lb/hr
0.57 kg/hr
2.60 lbs/hr
16.50 lbs/hr
7.50 kgs/h
# of Holes
Diameter
Disc Thickness
0.5 Rev./min
(11.5 RPM)
28.65 lbs/hr
13.80 kgs/hr
91.70 lbs/hr
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
15 grams/rev
0.94 kg/hr
0.20 lb/hr
33.30 kgs/hr
13.2 lbs/hr
1.17 kgs/hr
0.26b/hr
41.60 kgs/hr
8.25 lbs/hr
DP30 250940
P250940
0.2 Rev./min
(6.4 RPM)
7.82 g/Rev.
0.20 g/Hole
9.76 g/rev.
# of Holes
Diameter
Disc Thickness
0.093 kg/hr
0.46 lb/hr
0.21 kg/hr
1.00 lb/hr
0.47 kg/hr
3.00 kgs/hr
10.55 lbs/hr
4.78 kgs/hr
36.70 lbs/hr
16.65 kgs/hr
0.245 g/hole
0.115 kg/h
0.60 lb/hr
0.27 kg/hr
1.30 lbs/hr
0.58 kg/hr
3.75 kgs/h
13.57 lbs/hr
6.15 kgs/hr
45.85 lbs/hr
20.80 kgs/hr
0.5 Rev./min
(11.5 RPM)
1.0 Rev./min
(35.5 RPM)
Default
Calibration #
7.8 grams/rev
65
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Specification Sheet
DIGITAL DOSING UNIT TECHNICAL PARAMETERS
Disc Dosing Factor Table 2
Maximum Number of Feed Stations One (1) for Granule
Processing
Maximum Product Temperature
Weight (Approximately)
Connected Loads
Operating Voltage
Special Voltage
80oC (or 176 oF)
20 kg (44 pounds)
0.11 kW
115/1/60 or 230/1/50-60
On Request
Option
Option
Hopper Level Probe (Additive)
Hopper Level Probe (Virgin)
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Starter Calibration Parameters
DD Discs
Disc
Calibration Number
1.75
DD 30-030673
Parameters
Default Units
Percent
Description
1
2
3
4
Additive %
Using the arrow keys, set additive ratio.
Shot size of the current mold
Screw recovery time
Grams/pounds
Seconds
Using the arrow keys, set the shot size of the current capacity in grams/min or pounds/min.
Using the arrow keys, set the screw recovery time (in seconds)
Enter a value from the tables below and proceed to calibration mode to set the calibration value.
Calibration weight for additive
Totalizer (display only)
Grams
18
Grams/pounds
Digital Dosing unit parameter setup 1-4 for extrusion - contant
Parameters
Additive %
Default Units
Percent
Description
1
2
Using the arrow keys, set additive ratio.
throughput
Not used
Grams/pounds
Using the arrow keys, set to the throughput of the extruder capacity in grams/min or pounds/min
3
4
Calibration weight for additive
Totalizer (display only)
Grams
Enter a value from the tables below and proceed to calibration mode to set the calibration value.
18
Grams/pounds
67
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Digital Dosing unit parameter setup 1-4 for extrusion proportional
Parameters
Additive %
Default Units
Percent
Description
1
2
Using the arrow keys, set additive ratio.
throughput
Grams/pounds
RPM
Using the arrow keys, set to the throughput of the extruder capacity in grams/min or pounds/min
Using the arrow keys, set the RPM
3
Extruder speed
4
Calibration weight for additive
Totalizer (display only)
Grams
Enter a value from the tables below and proceed to calibration mode to set the calibration value.
18
Grams/pounds
Set-up of Factory Set Operating Parameters
Digital Dosing unit parameter setup 7-14
Bison - Black motor
Bauer - Blue motor
Comments
Parameter
RPM
2
6
12
38
6.4
11.5
35.5
7
8
9
65000 25200 14103 4387
11739 6600
2135
These values refer to the pulses of the encoder
Nominal motor current
0.5
0.7
Ext
Inj
Ext
Inj
1040
16
1040
16
(see separate calculation sheet for parameter #9)
Factory set, do not change
10
11
0
1
Ext
Inj
Ext
Inj
50
50
50
50
Ext = minimum input frequency w/follower only
Inj = Minimum # of machine cycles per dosing
12
Ext
Inj
Ext
Inj
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10
5.56
10
5.56
Ext = Span factor (sf) calculated using: sf=1000/rpm@10vdc
sf = 1000/rpm @20ma
13
14
Ext
0
Inj
0
Ext
0
Inj
0
Communication address used with Euromap 17 (use 1 instead of 0)
For use with Micro mix hopper (use 1 instead of 220)
Ext
220
Inj
220
Ext
220
Inj
220
69
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Station 1 Digital Dosing Unit
SIDE VIEW
TOP VIEW
71
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Station 2 Digital Dosing Unit
SIDE VIEW
TOP VIEW
72
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General Wiring Diagram for Bauer Motor
73
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Dosing Unit Electrical Schematic Chart for Bauer (blue) motors only
Drawing No. Description of Drawing
Voltage
110
CT102020
CT102021
CT102022
CT102023
CT102024
CT102025
CT102026
CT102027
Note:
C150 CONTROLLER INJECTION
C150 CONTROLLER EXT-S SIMPLE EXTRUSION
C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT
C150 CONTROLLER EXT-C EXTRUSTION 0-20 mA INPUT
C150 CONTROLLER INJECTION
110
110
110
220
C150 CONTROLLER EXT-S EXTRUSION SIMPLE EXTRUSION
C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT
C150 CONTROLLER EXT-C EXTRUSION 0-20 mA INPUT
220
220
220
1. If changes to the controller are required, please consult factory.
2. Request any additional drawings needed at that time.
Dosing Unit Electrical Schematic Chart for Bison (black) motors only
Drawing No. Description of Drawing
Voltage
110
CT101674
CT101675
CT101676
CT101677
CT101753
CT101750
CT101751
CT101752
Note:
C150 CONTROLLER INJECTION
C150 CONTROLLER EXT-S SIMPLE EXTRUSION
C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT
C150 CONTROLLER EXT-C EXTRUSTION 0-20 mA INPUT
C150 CONTROLLER INJECTION
110
110
110
220
C150 CONTROLLER EXT-S EXTRUSION SIMPLE EXTRUSION
C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT
C150 CONTROLLER EXT-C EXTRUSION 0-20 mA INPUT
220
220
220
1. If changes to the controller are required, please consult factory.
2. Request any additional drawings needed at that time.
75
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Appendix D: Spare Parts List
Dosing Disc/Shear Order Numbers
Dosing disc
72 chambers
CT 100562
CT 21710
CT 21711
CT 2057
49 chambers
25 chambers
18 chambers
Dosing disc, wear-resistant
40 chambers
CT 28214
CT 27141
CT 27142
25 chambers
18 chambers
Shear for DD style unit
18, 25, 40 pocket disc
72 pocket disc
CT 21392
CT 100875
Replacement Motor Order Numbers
Bauer Gear Motors
6.4 RPM
11.5 RPM
35.5 RPM
CT34300
CT102241
CT34299
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Control System Order Numbers
Fuse
F1
F2
F3
F4
Size
5X20
1/4X1
5X20
5X20
5X20
5X20
Voltage
250 V
1/4-250 V
250 V
250 V
250 V
Amps
5 A
4 A
0.5 A
0.5 A
0.5 A
0.5 A
Type
Metric
Time Delay
Time Delay
Metric
Part Number
A0571836
CT99107
CT96398
CT102258
CT102259
A0571836
F5
F7
Metric
Metric
250 V
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-Notes-
78
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Technical Assistance
Parts Department
[
]
Call toll-free 7am–5pm CST: 800 783-7835
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
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Call toll-free 24 hours at: 800 783-7835
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
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Call 262 641-8610 Monday–Friday, 8am–5pm EST
Our products are sold by a worldwide network of independent sales representatives. Contact
our Sales Department for the name of the sales representative nearest you.
Contract Department
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Call 262 641-8610 Monday–Friday, 8am–5pm EST
Let us install your system. The Contract Department offers any or all of these services: project
planning; system packages including drawings; equipment, labor, and construction materials;
and union or non-union installations.
Sterling
2900 S. 160th Street
New Berlin, WI 53151
262-641-8610
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