Sterling BF3-600 - Manuals

Digital Dosing Units 5 1.1 Controller The Digital Dosing additive feeder consists of a controller, dosing motor, and feeder(s). The controller is used to • Enter, recall, and run recipes • To run, monitor, and stop the dosing process • To calibrate • To troubleshoot problems via error codes • To con...

Digital Dosing Units 6 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 valu...

Digital Dosing Units 7 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 ONL...

Digital Dosing Units 8 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 al...

Digital Dosing Units 9 3. Press Input to display #2, “Shot size of current mold”. Using arrow keys, set the total shot size (parts and runners) of the current mold capacity in grams. 4. Press Input to display #3, “Screw recovery time”. Using arrow keys, set the screw recovery time (in seconds). For ...

Digital Dosing Units 10 6. Repeat step #19 four more times, each time entering the new weight from the scale into the controller using the arrow keys. Sometimes the values won’t change, or sometimes they may only change by a few tenths of a gram. The controller keeps a running average of all calibra...

Digital Dosing Units 11 Section 3: Initial Installation And Operation 3.1 Initial Installation Direction of Material Flow Hopper Piece Processing Machine Figure 4. Digital Dosing Unit Assembly 1. The Digital Dosing additive feeder is not affected by machine vibration, therefore best performance is a...

Digital Dosing Units 12 be exposed to extreme heat (maximum temperature 45 ° C or 115 ° F) or excessive moisture. 4. Electrical connection to process machine: • Injection Molding : Connect the cycle/run slave cable (thin two-conductor cable) to a set of DRY (NO VOLTAGE) contacts that CLOSE for the d...

Digital Dosing Units 13 NOTE: Zero input corresponds to zero screw speed and no additive dosing. Maximum input corresponds to maximum screw speed. NOTE: If a 0-10kHz frequency input is used, it must be a square wave with an amplitude of 12VDC. The shape of the signal is important, especially above 7...

Digital Dosing Units 15 • Enter the additive percentage by using the Arrow Keys . (The range of values that can be entered is 0.01% to 50.00%. The arrow keys are used to change all process variables. The double arrow key allows the user to ramp up or down by larger increments.) Step 2: • Press Input...

Digital Dosing Units 17 • 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 th...

Digital Dosing Units 18 1. Pressing again will first display the number “18” and then will display the total throughput in kilograms (totalizer). Operation-Injection Molding 1. Ensure that the unit is properly installed (Section 3.1), a recipe is entered (section 3.3.1), and the feeder is calibrated...

Digital Dosing Units 19 light on the controller during screw recovery. The disc symbol will light when the Digital Dosing unit is dosing material. • The totalizer will increase after each cycle by the amount of material dosed. • To stop the dosing process, press . • While the unit is dosing, the cur...

Digital Dosing Units 21 • Press a third time. • The machine displays a flashing , “g” or “lb” and a number “4”flashes on the display (because this is Extrusion Constant, step 3 is skipped). • After the “4” flashes on the display, a number in the format xxxx.x will come up. • Enter the calibration we...

Digital Dosing Units 22 Step 5: 6. Press again. 7. The number “18” will be displayed before the total throughput in kg is displayed. Operation –Extrusion Constant 1. Ensure that the unit is properly installed (Section 3.1), a recipe is entered (Section 3.4.1), and the feeder is calibrated (Section 3...

Digital Dosing Units 23 NOTE: See Appendix A, Troubleshooting, for information on problems or errors encountered and their resolution . 3.5 Extrusion Proportional Recipe Input – Extrusion Proportional To enter a recipe for Extrusion Proportional, the following process data is required: • Percentage ...

Digital Dosing Units 25 Step 4: 1. Press a fourth time. 2. The machine displays a flashing and “ g ”. 3. After “4” flashes quickly on the screen, a number in the format xxx.xx will come up on the display. • Enter the calibration weight in grams or pounds. If the calibration weight is unknown, enter ...

Digital Dosing Units 26 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 th...

Digital Dosing Units 27 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, t...

Digital Dosing Units 28 • 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 calib...

Digital Dosing Units 30 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...

Digital Dosing Units 31 • Press and hold the button until the totalizer display returns to the screen. • The recipe is now stored under the selected ID number. Recipe Recall Step 1: • Press the stop button to stop any current applications. Step 2: • Press the Storage/Recall key ( ) once. • A two-dig...

Digital Dosing Units 32 • 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...

Digital Dosing Units 33 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 a...

Digital Dosing Units 34 Mixer An optional mixer is available that can be mounted under the Digital Dosing unit. The mixer is used to help distribute fine powders and granules. During the injection molding process, the mixer only runs during screw recovery (when the Digital Dosing unit is dosing addi...

Digital Dosing Units 35 Figure Section 5: Maintenance 5.1 Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the on/off Switch. Every 3 months: Check scraper in dosing station DD/DT. Every 6 months: Check all electrical and m...

Digital Dosing Units 36 6. Remove the dosing unit from the dosing motor. 7. Remove the cover from the connecting piece (D). 8. Loosen the two screws (C) on the underside of the dosing unit housing (E). 9. Remove the scraper (A). Installing the scraper 1. Place the new scraper in the dosing unit hous...

Digital Dosing Units 37 5. Remove the dosing hopper from the dosing unit. 6. Dismantle the dosing unit and remove the scraper (D). 7. Loosen the two hexagon socket screws (B, M6 x 30) on the top side of the dosing disc (A). 8. Loosen the center hexagon socket screw (C, M6 x 12) and replace by an M6 ...

Digital Dosing Units 38 5.4 Changing the Dosing Disc in the Digital Dosing Dosing Station Removing the Dosing Disc 1. Empty the dosing station. 2. Switch the control unit off by means of the on/off switch. 3. Dismantle the dosing unit and remove the scraper. 4. Loosen the two hexagon socket screws (...

Digital Dosing Units 39 Installing Different Types of Dosing Discs Dosing discs of the same type may be exchanged for each other without any problems. If dosing discs with a different compartment number are installed, this has to be entered in the control system! 1. Enter the (preliminary) calibrati...

Digital Dosing Units 40 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 u...

Digital Dosing Units 41 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 f...

Digital Dosing Units 42 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. M...

Digital Dosing Units 43 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 conn...

Digital Dosing Units 44 ERROR CODES Code Definition Possible Reason/Solution A001 Strap “safety switch” is missing. Manufacturer Service. A002 The nominal current of the dosing motor (=100%, see name plate) is being exceeded for more than 2 seconds by 30% or for a maximum of 0.5 seconds by 80%. Dosi...

Digital Dosing Units 45 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 t...

Digital Dosing Units 46 Disc RPM ( Additive - %) x (Total Extruder Throughput - lb / hr) 13.22 x (Disc Calibration Weight - g) = Recipe Limitations Extrusion Motor Assembly Speed (RPM) Maximum Speed (RPM) 12 12.5 38 40.0

Digital Dosing Units 47 Appendix B: Basic Parameter Settings Extrusion Mode: You need an extruder signal that is proportional to the extruder speed to operate in the Extrusion Proportional mode. You can use any of the following: • Frequency signal (must be 12VDC square wave) • 0-20mA current signal ...

Digital Dosing Units 48 If a current signal is available (0 - 20 mA) calculate the frequency output of the extruder for the lower / upper working area using the formula: Frequency [Hz] = Input current [mA] x 10000 [Hz] 20 [mA] Note the data: Min. input frequency = __________ Hz Max. input frequency ...

Digital Dosing Units 50 Totalizer displayed in lb (kg default) . . . . . . . . . . . . . . . . . . . . . . . . . 16 ___ Shotweight up to 6.5 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 or Shotweight 6.5 to 65 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

54 Appendix C: Disc Dosing Factor s And Equipment Drawings And Parts Numbers Disc Dosing Factor Table 1: Disc Guide Disc Disc Nomenclature Us ed in th e Con troller Minimum/ Maximum Disc Re volution Weight Per Disc Re volution (Bulk De nsity 35lb/cuft) M in. Thr oughput with 100% Continuo us Run nin...

58 Specification Sheet DIGIT A L DOSING UNIT T E CHNICAL PARAMETERS Disc Dosing Factor Table 2 M axi m um Num ber of Feed S tat ions One ( 1) f or G ranul e Pr ocessi ng M axi m um Product Tem perat ure 80 o C (o r 17 6 o F) W eigh t (Ap pr ox im ately) 20 kg (4 4 pou nd s) Connected L oa ds 0.11 kW...

61 Station 1 Digital Dosing Unit SIDE VIEW TOP VIEW

62 Station 2 Digital Dosing Unit SIDE VIEW TOP VIEW

63 Dosing Unit Electrical Schematic Chart Drawing No. Description of Drawing Voltage CT102020 C150 CONTROLLER INJECTION 110 CT102021 C150 CONTROLLER EXT-S SIMPLE EXTRUSION 110 CT102022 C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT 110 CT102023 C150 CONTROLLER EXT-C EXTRUSTION 0-20 mA INPUT 110 CT1020...

64 Appendix D: Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers ID 100562 49 chambers ID 21710 25 chambers ID 21711 18 chambers ID 2057 Dosing disc, wear-resistant 40 chambers ID 28214 25 chambers ID 27141 18 chambers ID 27142 Shear for DD style unit 18, 25, 40 pocket disc ID...

66 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’...