Page 2 - Table of Contents
Digital Dosing Units 2 Table of Contents SECTION 1: INTRODUCTION …………….……………………….……….........................3 1.1 C150 Controller... .................................................................................... .5 1.2 Keys and Symbols ............................................................
Page 3 - Section 1: Introduction; manual covers the operation of both units.
Digital Dosing Units 3 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 po...
Page 4 - Figure 2. Dual Station Digital Dosing Unit
Digital Dosing Units 4 Figure 2. Dual Station Digital Dosing Unit (Shown with optional virgin supply hopper and controller mounting plate)
Page 5 - Configure the unit to the desired process.
Digital Dosing Units 5 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 re...
Page 6 - Stop
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...
Page 7 - Symbols
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...
Page 8 - and easily. Please refer to the manual to go into greater detail.; INJECTION MOLDING
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...
Page 9 - of additive material.
Digital Dosing Units 9 Recipe Setup for Injection Molding: 1. Turn power switch to ON position. 2. Press Input to display # 1, “Additive %”. Using arrow keys, set additive ratio. 3. Press Input to display #2, “Shot size of current mold”. Using arrow keys, set the total shot size (parts and runners) ...
Page 10 - Recipe Setup for Extrusion:
Digital Dosing Units 10 Recipe Setup for Extrusion: 1. Turn power switch to ON position. 2. Press Input to display # 1, “Additive %”. Using arrow keys, set additive ratio. 3. Press Input to display # 2, “Throughput of extruder”. Using arrow keys, set the total extruder throughput in g/min or lb/min....
Page 11 - is now ready to begin operation.
Digital Dosing Units 11 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 re...
Page 12 - Basic Input Parameters for Digital Dosing Feeder with; Blue
Digital Dosing Units 12 Basic Input Parameters for Digital Dosing Feeder with Injection Software (P1._ _ - Older units) or (P2._ _ - newer units) Hold Stop and Input buttons until “7” flashes - Enter the input number for the specific motor from the table below. - This value sets the impulses of the ...
Page 13 - Press; button; button
Digital Dosing Units 13 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 fo...
Page 16 - Basic Input Parameters for Colorblend C-150 with
Digital Dosing Units 16 Basic Input Parameters for Colorblend C-150 with Extrusion Software (E1._ _ - Older units) or (E2._ _ - newer units) Hold Stop and Input buttons until “7” flashes - Enter the input number for the specific motor from the table below. - This value sets the impulses of the encod...
Page 20 - Section 3: Initial Installation and Operation; Initial Installation; Figure 4. Digital Dosing Unit Assembly
Digital Dosing Units 20 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...
Page 21 - Figure 5. Electrical Diagram; Extrusion - Proportional; . Please refer to the labels on the cycle/run
Digital Dosing Units 21 4. Electrical connection to process machine: • Injection Molding: Connect the cycle/run slave cable (thin two-conductor cable) to a set of DRY (NO VOLTAGE) contacts that CLOSE for the duration of screw recovery. See Figure 5, electrical diagram. J12-3 J12-2 Relay contact Inje...
Page 22 - Figure 6. Analog Inputs; Extruder Follower Interface Signal Converter; Signal Converter with AC Power Supply
Digital Dosing Units 22 J12-4 _ J12-3 + 0-10 VDC or 0-20 mA Extruder output Digital Dosing controller (diagram of analog inputs) Figure 6. Analog Inputs 5. Make sure the unit is turned OFF before plugging it in. The switch toward the rear of the controller unit should be in the OFF, or “O” position....
Page 23 - Signal Converter with DC Power Supply; Initial Operation; . Extrusion operations require a “span factor” to be
Digital Dosing Units 23 Signal Converter with DC Power Supply This module requires a separate 24 VDC power supply. Vendor: Phoenix Contact Order Designation: MCR-FL-C-UI-2UI-DCI-NC Supply Voltage: 20 to 30V DC Input 4-20 mA, 0-10V (Quantity: 1) Output 0-20 mA, 0-10V (Quantity: 2) 24 VDC Mini Power S...
Page 24 - Molding
Digital Dosing Units 24 • This section will show how to calibrate the unit, bring the unit on line, enter a recipe, and store and recall recipes. 3.3 Injection Molding During each molding cycle the Digital Dosing unit doses the correct amount of additive evenly throughout the screw recovery cycle. T...
Page 25 - lb; “3” = screw recovery time in seconds; screw
Digital Dosing Units 25 Step 2: • Press Input again. • The symbols “ g ,” or “ lb ”, “ min ” and the screw symbol flash. • After the “2”quickly flashes on the display, a number in the format xx.xxx will come up on the display. • Enter the shot weight using the arrow keys. The range of values that ca...
Page 26 - Press Input; printer is configured.; if you have a blending unit and have invoked this option
Digital Dosing Units 26 Step 4: “ 4 “ = calibration weight in grams or pounds • Press Input a fourth time. • The symbols “ g ” or “ lb ”and flash. • After “4” quickly 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 cal...
Page 27 - Pressing; if it is available; By using the arrow keys, you can choose your printer parameters.
Digital Dosing Units 27 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...
Page 28 - Operation - Injection Molding; If desired, clear the totalizer by holding the Stop key (
Digital Dosing Units 28 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 ( ) con...
Page 29 - encountered and their resolution.; . If the process requires the additive to be dosed in proportion to; Recipe Input – Extrusion - Constant
Digital Dosing Units 29 • To stop the dosing process, press . • While the unit is dosing, the current recipe can be viewed, but not modified by pressing . The recovery time displayed in the current recipe is the average of the last five shots measured from the molding machine. To change the recipe, ...
Page 30 - Extrusion Constant, parameter “3” is skipped.; “ 4 “ = calibration weight in grams or pounds; or
Digital Dosing Units 30 • Enter the additive percentage by using the Arrow Keys . The range of values that can be entered is 0.01 to 50.00%. The arrow keys are used to change all process variables. The double arrow key allows the user to ramp up or down at a faster rate. Step 2 : • Press again. • Th...
Page 33 - Operation – Extrusion - Constant
Digital Dosing Units 33 Operation – Extrusion - Constant 1. Ensure that the unit is properly installed (Section 3.1), a recipe is entered (Section 3.4.1), and the feeder is calibrated (Section 3.6), before attempting to begin operation. 2. If desired, clear the totalizer by pressing continuously for...
Page 34 - Recipe Input – Extrusion Proportional
Digital Dosing Units 34 3.5 Extrusion – Proportional (Extruder Follower Option) Recipe Input – Extrusion Proportional To enter a recipe for Extrusion Proportional, the following process data is required: • Percentage of additive • Expected throughput of the extruder during production • Extruder scre...
Page 36 - printer is configured
Digital Dosing Units 36 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...
Page 37 - Operation – Extrusion – Proportional (Extruder Follower Option)
Digital Dosing Units 37 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 calibrate...
Page 38 - since calibration weight differs from material to material.; Determining the Calibration Weight; To start the calibration process, press the calibration key.
Digital Dosing Units 38 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 dose...
Page 40 - calibration weight.
Digital Dosing Units 40 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 th...
Page 41 - Section 4: Advanced Operations/ Control Functions; Recipe Storage and Recall; at any time will exit the Recipe Storage/Recall mode.; Recipe Storage; Use the Arrow keys
Digital Dosing Units 41 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...
Page 42 - Recipe Recall
Digital Dosing Units 42 Step 3: • Press and hold the button until the totalizer display returns to the screen. • The recipe is now stored under the selected ID number. Recipe Recall Step 1: • Press the stop button to stop any current applications. Step 2: • Press the Storage/Recall key ( ) once. • A...
Page 43 - Clearing the Totalizer; must be corrected
Digital Dosing Units 43 Step 4: • Press and hold until the totalizer appears on the screen. • The recipe is now active and can be run or edited. NOTE: The recalled recipe now becomes the active recipe. 4.2 Clearing the Totalizer • The totalizer displays the total amount of additive dosed since the l...
Page 44 - Optional Equipment, Level Switches and Communications; with a flashing alarm symbol
Digital Dosing Units 44 4.4 Optional Equipment, Level Switches and Communications Options Optional equipment for the Digital Dosing Additive Feeder includes: Alarms Several alarm options are available for the Digital Dosing feeder. The standard unit comes with a flashing alarm symbol on the faceplat...
Page 45 - control lamp should now switch on again. If not, repeat Step 4.; Communication Protocol Interfaces
Digital Dosing Units 45 NOTE: Turning the trim-pot to the left decreases the switching sensitivity; turning it to the right increases the switching sensitivity. 5. Fill the dosing station until the level probe is two-thirds covered. The yellow control lamp should now switch on again. If not, repeat ...
Page 46 - Section 5: Maintenance; Maintenance Intervals; Removing the shear plate
Digital Dosing Units 46 Figure Section 5: Maintenance 5.1 Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the “On/Off” Switch. Every 3 months: Check shear plate in “DD” dosing station, and wiper in “DT” dosing station. Eve...
Page 47 - Installing the shear plate; Cleaning the “DD” Digital Dosing Station; Dismantling the Dosing Station
Digital Dosing Units 47 6. Remove the dosing unit from the dosing motor. 7. Remove the cover from the connecting piece (D). 8. Loosen the two screws (C) on the underside of the dosing unit housing (E). 9. Remove the shear plate (A). Installing the shear plate 1. Place the new shear plate in the dosi...
Page 48 - Installing the Dosing Station
Digital Dosing Units 48 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...
Page 49 - Changing the Dosing Disc in the “DT” Digital Dosing Station; Removing the Dosing Disc; See Appendix D: Spare Parts List on page 61 for disc part numbers.
Digital Dosing Units 49 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...
Page 50 - Installing Different Types of Dosing Discs; installed, this has to be entered in the control system!; DD Discs; Execute “calibration” to determine the final calibration value; Removing / Replacing the Wiper in the DT Dosing Station; Loosen the 3 plastic screws on
Digital Dosing Units 50 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 sys...
Page 51 - (Use only plastic screws to avoid damage to the extruder or; molding machine screw should the mounting screws ever come loose.); Cleaning the DT Dosing Station
Digital Dosing Units 51 8. Tighten down the 3 plastic screws. Make sure that the wiper is fitted parallel to the dosing plate (Use only plastic screws to avoid damage to the extruder or molding machine screw should the mounting screws ever come loose.) 9. Install the dosing container along with the ...
Page 52 - Stations; the freshly installed
Digital Dosing Units 52 16. Mount the safety screws. 17. Install the dosing container along with the dosing hopper on the dosing housing (pay attention to the guide pins). 18. Mount the profile clamp. 19. Mount the screw at the profile clamp and tighten. 5.7 Exchangeable Stations Dosing discs of the...
Page 53 - Fuses
Digital Dosing Units 53 5.8 Replacing Fuses 1. Stop the continuous operation. 2. Wait until the dosing unit has stopped. 3. Switch off the device with the on/off switch. 4. Cut off the voltage supply. 5. Wait at least one minute before starting to work at the unit or controller. 6. Never try to repa...
Page 54 - Appendix A: Troubleshooting; A.1 General Troubleshooting - Unit Will Not Operate; Dosing unit for the process and installation, see Section 2.
Digital Dosing Units 54 Appendix A: Troubleshooting During setup and use of the Digital Dosing Additive Feeder, personnel may experience difficulties. Some of the problems encountered may be resolved using the following techniques. A.1 General Troubleshooting - Unit Will Not Operate • Check all conn...
Page 55 - ERROR CODES
Digital Dosing Units 55 ERROR CODES Code Definition Possible Reason/Solution A001 Strap “safety switch” is missing. Manufacturer Service. A002 The nominal current of the dosing motor (=100%, see name plate) is being exceeded for more than 2 seconds by 30% or for a maximum of 0.5 seconds by 80%. Dosi...
Page 56 - A.3 Determining the Software Setup Factor; Injection Molding; Disc RPM; Recipe Limitations for Injection Molding
Digital Dosing Units 56 A.3 Determining the Software Setup Factor The Digital Dosing control unit is configured via a Software Setup Factor (binary code). To determine the Software Setup Factor answer the following questions: If the answer is “yes” enter the code number in the selection column. If t...
Page 57 - Extrusion; Recipe limitations are listed in the table following the recipe.; Recipe Limitations Extrusion
Digital Dosing Units 57 Extrusion For extrusion applications compute the dosing disc speed using the following formula. Recipe limitations are listed in the table following the recipe. Disc RPM ( Additive - %) x (Total Extruder Throughput - lb / hr) 13.22 x (Disc Calibration Weight - g) = Recipe Lim...
Page 58 - Appendix B: Basic Parameter Settings; voltage
Digital Dosing Units 58 Appendix B: Basic Parameter Settings Extrusion Mode: You need an extruder signal that is proportional to the extruder speed to operate in the Extrusion - Proportional mode. You can use any of the following: • Frequency signal (must be 12 VDC square wave) • 0 - 10 VDC signal •...
Page 59 - span factor; Rotational speed of the extruder [rpm]x 10; Example; Level probes: raw material and additive probes installed
Digital Dosing Units 59 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 ...
Page 60 - Totalizer displayed in lbs
Digital Dosing Units 60 • Throughput: 8000 g/min • Totalizer displayed in lbs • Extrusion mode Raw material probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Additive probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Blend...
Page 61 - Level probes: additive probe installed
Digital Dosing Units 61 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-...
Page 63 - Appendix C: Dosing factors, equipment drawings and part numbers; Disc Dosing Factor Table 1: Disc Guide
63 Appendix C: Dosing factors, equipment drawings and part numbers Disc Dosing Factor Table 1: Disc Guide Disc Disc Nomenclature Used in the Controller Minimum/ Maximum Disc Revolution Weight Per Disc Revolution (35 lbs/cu. ft.) Min. Throughput with 100% Continuous Running (35 lbs./cu. ft.) Max. Thr...
Page 66 - Specification Sheet
66 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 80 o C (or 176 o F) Weight (Approximately) 20 kg (44 pounds) Connected Loads 0.11 kW Operating Voltage 115/1/60 or 230...
Page 67 - Starter Calibration Parameters
67 Starter Calibration Parameters DD Discs Disc Calibration Number DD 30-030673 1.75 Parameters Default Units Description 1 Additive % Percent Using the arrow keys, set additive ratio. 2 Shot size of the current mold Grams/pounds Using the arrow keys, set the shot size of the current capacity in gra...
Page 71 - Station 1 Digital Dosing Unit
71 Station 1 Digital Dosing Unit SIDE VIEW TOP VIEW
Page 73 - General Wiring Diagram for Bauer Motor
Page 76 - Appendix D: Spare Parts List; Dosing Disc/Shear Order Numbers; Replacement Motor Order Numbers
76 Appendix D: Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers CT 100562 49 chambers CT 21710 25 chambers CT 21711 18 chambers CT 2057 Dosing disc, wear-resistant 40 chambers CT 28214 25 chambers CT 27141 18 chambers CT 27142 Shear for DD style unit 18, 25, 40 pocket disc CT...
Page 77 - Control System Order Numbers
77 Control System Order Numbers Fuse Size Voltage Amps Type Part Number F1 5X20 250 V 5 A Metric A0571836 F2 1/4X1 1/4-250 V 4 A Time Delay CT99107 F3 5X20 250 V 0.5 A Time Delay CT96398 F4 5X20 250 V 0.5 A Metric CT102258 F5 5X20 250 V 0.5 A Metric CT102259 F7 5X20 250 V 0.5 A Metric A0571836
Page 79 - Technical Assistance; Parts Department
73 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...
