Page 3 - Shipping Info; Do not; please contact the parts and service department
882.01749.00 iii Shipping Info Unpacking and Inspection You should inspect your granulator for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the E...
Page 4 - Table of Contents
882.01749.00 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..........................
Page 6 - -1 How to Use This Manual
882.01749.00 6 of 93 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only cor...
Page 8 - -4 Warnings and Precautions
882.01749.00 8 of 93 1-4 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, NEPA or CE and any othe...
Page 9 - Chapter 2: Functional Description; when equipped with the appropriate dosing module
882.01749.00 9 of 93 Chapter 2: Functional Description 2-1 Introduction This manual is to be used with the Digital Dosing Disc additive feeder. The feeder precisely meters and controls the addition of color concentrates, master batches, additives, regrind, and other materials to plastic processing s...
Page 10 - Figure 2. “Duo” Dual Station Digital Dosing Feeder; Controller; Configure the feeder to the desired process.
882.01749.00 10 of 93 Figure 2. “Duo” Dual Station Digital Dosing Feeder 2-1 A250 Controller The Digital Dosing additive feeder consists of a controller(s), dosing motor(s), and dosing module(s). The controller is used to: Configure the feeder to the desired process. Calibrate the feeder. Run, monit...
Page 11 - DO; NOT; ACCEPT; immediately; INJECTION MOLDING; closes
882.01749.00 11 of 93 2-2 Quick Start-Up Guide (See Chapter four for complete description) This “Quick Start” section is intended to help you start your Digital Dosing feeder quickly and easily. Please refer to the enclosed O & I manual for additional information. Unpacking: 1. Inspect package f...
Page 12 - EXTRUSION – “Simple”; contact; EXTRUSION – “Follower”; Feeder Configuration - Injection Molding:; Feeder
882.01749.00 12 of 93 6. EXTRUSION – “Simple” : Connect the input cable (2-conductor cable-gray) to a dry contact (zero voltage) signal that indicates the extruder screw is turning. ( The connection in the controller should be on terminal block #10 and PLC input X5.. A jumper wire can also be instal...
Page 14 - GR; Injection; Virgin material sensor.
882.01749.00 14 of 93 GR or OZ. Select the measure commonly used at your facility. Injection Press (GR/KG/OZ/LB) Select the measure commonly used at your facility. Additive sensor. Select the no sensor, alarm only, or alarm & stop. Virgin material sensor. Select the no sensor, alarm only, or ala...
Page 15 - Turn power switch to “ON” position.; Shot Size
882.01749.00 15 of 93 Recipe Setup - Injection Molding: Turn power switch to “ON” position. Injection molding. In order to calculate the correct motor speed required to feed the desired amount of additive, the following data must be entered: 1) Additive % 2) Shot Size 3) Screw Recovery Time. 4) Cali...
Page 16 - must; “DD” Pellet Discs; mm
882.01749.00 16 of 93 Screw Recovery Time. The screw recovery time is the estimated screw recovery time, and is used as the initial value for validating the recipe. Actual screw recovery times as measured by the presence of the screw recovery signal, are used to fine-tune the feed rate during operat...
Page 17 - “DT” Pellet & Regrind Discs; Additive Sample weighing.; at
882.01749.00 17 of 93 “DT” Pellet & Regrind Discs “DP” Powder Discs Additive Sample weighing. Weighing samples of additive provides for more precise control of feed rate. Up to 5 samples can be weighed. All weights entered are averaged to arrive at a value to be used during operation. The weighi...
Page 19 - Drive tuning; GR or OZ; Extrusion
882.01749.00 19 of 93 Drive tuning . Perform drive tuning. See section # for details. Speed Alarm setup . Select alarm option – Alarm & stop, alarm only, or no alarm. GR or OZ Select the measure commonly used at your facility. Extrusion Press (GR/KG/OZ/LB) Select the measure commonly used at you...
Page 20 - Recipe Setup for Simple Extrusion:
882.01749.00 20 of 93 Virgin material sensor. Select the no sensor, alarm only, or alarm & stop. Recipe Setup for Simple Extrusion: 1. Turn power switch to “ON” position. In order to calculate the correct motor speed required to feed the desired amount of additive, the following data must be ent...
Page 22 - Feeder Configuration – Extrusion follower:
882.01749.00 22 of 93 “DT” Pellet & Regrind Discs “DP” Powder Discs Feeder Configuration – Extrusion follower: Touch the ACS logo on the main menu screen to access the configuration menu. See section # for details. Feeder Type Selection . Select extrusion follower. Select press signal type, 0-10...
Page 31 - Chapter 3: Installation and Operation; Figure 4. Digital Dosing Feeder Assembly; smooth to promote consistent material flow.
882.01749.00 31 of 93 Chapter 3: Installation and Operation 3-1 Installation Direction of Material Flow Hopper Piece Processing Machine Figure 4. Digital Dosing Feeder Assembly 1. The Digital Dosing additive feeder is not affected by machine vibration, so the best performance is achieved by mounting...
Page 32 - optional; must not be exposed to temperatures above 45
882.01749.00 32 of 93 2. The following applications require a larger feed stand ( optional 3” or 4”) to prevent material bridging: o Machines with a total throughput over 200 lbs./hr. o Machines running regrind larger than 5/16” screen size o Processes with a high percentage of regrind (>30%) o N...
Page 33 - The connection; Extrusion - Proportional; or; NOTES
882.01749.00 33 of 93 Extrusion - Constant : Wire the “cycle/run” cable (two- conductor gray cable) to a set of dry (NO VOLTAGE) contacts that CLOSE when the screw rotates. (See Figure 5.) The connection inside the controller should be on terminal block #10 and PLC input X5. Extrusion - Proportional...
Page 34 - Operation; These are also
882.01749.00 34 of 93 3-2 Initial Operation The control system is factory-programmed. However, specific values need to be verified prior to operation (basic parameter settings). The input values will be saved and still be available if the feeder is switched off, or a power failure occurs. Please ref...
Page 35 - Recipe Menu
882.01749.00 35 of 93 3-3 Recipes Recipe Menu The Recipe menu allows selection, editing, and deletion of recipes. The current recipe is displayed in the upper left corner. A different recipe can be selected by pressing the recipe value. Selecting a new recipe will automatically change the screen to ...
Page 38 - Simple Extrusion Recipe.
882.01749.00 38 of 93 Simple Extrusion Recipe. In order to calculate the correct motor speed required to feed the desired amount of additive, the following data must be entered: 4) Additive % 5) Throughput 6) Calibration weight. In addition, for the greatest accuracy, samples of the additive should ...
Page 39 - Extrusion Follower Recipe.
882.01749.00 39 of 93 Calibration weight. Calibration weight is determined from chart 5.1, and is dependant on the disc installed in the feeder. This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc. This weight is used as the initial value ...
Page 44 - screens; Status Screens
882.01749.00 44 of 93 Screen 8. The tray should be removed from the calibration chamber. The access cover should be replaced / closed. Weight Calibration is complete. Note that at any time in the process, the “Menu” button may be pressed to abort the weight calibration process. Any sample weights, i...
Page 45 - Common Elements
882.01749.00 45 of 93 Common Elements Buttons Press the Start button to begin feeding operation using the current recipe. Press the Stop button to end feeding operation. Press the Next button to display the next Status screen. There are 3 status screens available while the A250 is running: Totalizer...
Page 47 - Throughput Screen; Motor Speed Screen
882.01749.00 47 of 93 Totalizer Screen Displays total additive dosed since: A. Recipe change. Modifying the current recipe will not reset the total. Or B. Totalizer reset. The total is displayed in KG if recipe additive is measured in grams or kilograms. The total is displayed in LB if the recipe ad...
Page 48 - Screw Recovery Times Screen
882.01749.00 48 of 93 Displays the current motor speed when running, and the calculated speed when stopped. Screw Recovery Times Screen (Injection only) Displays the 5 most recent screw recovery times (latest on top), as well as the simple average and weighted average. Manual Run / Jog Screen This s...
Page 50 - System Setup Navigation Buttons.
882.01749.00 50 of 93 A) The Main Menu, using the Menu button. B) The System Setup Menu, using the Done button. C) The next Configuration screen, using the Next button. D) The previous Configuration screen, using the Prev button. System Setup Navigation Buttons. Navigates to the previous screen in t...
Page 56 - Speed Alarm
882.01749.00 56 of 93 Drive Tuning. The drive tuning screen is provided as an aid to tuning the drive to match the motor and load of the A250 feeder. Pressing the “Min” button will send the minimum drive signal to the controller. Pressing the “Max” button will send the maximum drive signal to the co...
Page 57 - Default Additive Measure
882.01749.00 57 of 93 Activate alarm screen & alarm outputs, and stop the feeder. See Status Screens section for speed alarm screen details. Default Additive Measure . This screen sets the default measure for additive weight in recipes. While the measure can be changed in any recipe, this screen...
Page 59 - Additive / Virgin Material Sensor
882.01749.00 59 of 93 Additive / Virgin Material Sensor . These screens select whether an additive (or virgin) material sensor is present and if so, what action to take when the sensor detects no material. Press the button in the upper right corner to sequence through the following options: No senso...
Page 60 - Press Signal Type
882.01749.00 60 of 93 Press Signal Type. (Extrusion Follower only) This screen selects the type of analog signal provided by the press to communicate the press speed. Press the button in the upper right corner to select from the following: 0 to 10 volts DC. (Default) 0 to 20 mA (milliamps) DC. 0 to ...
Page 63 - Features; Optional
882.01749.00 63 of 93 Analog / Encoder Monitor. This screen monitors the analog input & output, as well as the raw encoder value input. Additionally, the encoder can be connected to an alternate PLC input to help troubleshoot encoder problems. To change the encoder input, disconnect power & ...
Page 64 - Figure 7. Level Sensor Adjustment Screw; Turn the trim-pot until the yellow control lamp just switches off.
882.01749.00 64 of 93 LED Yellow (Station) on: Station Filled off: Station Emptied LED Green (Level Probe) on: Power Supply Available off: Power Supply Not Available Trim-pot with Plastic Screw M3 Cable Blind Lid Protective Screw npn: Normally Closed pnp: Normally Open 1 0 npn: Normally Open pnp: No...
Page 65 - Communication Protocol Interfaces
882.01749.00 65 of 93 Communication Protocol Interfaces The Digital Dosing feeder can be controlled remotely through ODBUS RTU protocol. Contact the Sales Department at 810.720.7300 for more information. OPTIONAL Additive Hoppers Various styles of additive hoppers and options are also available for ...
Page 67 - Virgin Material Supply Hoppers
882.01749.00 67 of 93 Virgin Material Supply Hoppers Various virgin material supply hopper options are available if your existing hopper will not work properly with the Digital Dosing feeder. Contact the Sales Department at 810.720.7300 for more information.
Page 68 - Chapter 4: Maintenance; -1 Preventative Maintenance Intervals
882.01749.00 68 of 93 Chapter 4: Maintenance 4-1 Preventative Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the “On/Off” Switch. Check shear plate and mounting hardware in “DD” dosing station. Every 3 months: Check wiper...
Page 69 - “DD” Dosing Module - Pellets
Page 70 - Removing the shear
882.01749.00 70 of 93 Figure 4-2 Removing the Shear Plate (“DD dosing Module) Removing the shear 1. Turn “Off” off the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches on the dosing motor. 4. Remove the dosing unit from the dosing motor. 5. Empty the dosing station. 6. Ope...
Page 71 - -3 Removing the “DD” Disc and Cleaning the Dosing Module; Dismantling the Dosing Module
882.01749.00 71 of 93 4-3 Removing the “DD” Disc and Cleaning the Dosing Module Dismantling the Dosing Module 1. Switch the control unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches on the dosing motor. 4. Remove the dosing unit from the dosing motor. 5....
Page 72 - Installing the Dosing Module; Place the dosing disc in the dosing unit housing.; Installing Different Types of Dosing Discs; number needs to be entered into the controller!; See Appendix D: Spare Parts List on page 61 for disc part numbers.
882.01749.00 72 of 93 Installing the Dosing Module 1. Remove the screw (M6 x 30 or 60) from the center hole. 2. Place the dosing disc in the dosing unit housing. 3. Screw the dosing disc in place with two (2) M6 x 30 socket screws, ensuring they are tight. 4. Re-install the center M6 x 12 socket scr...
Page 73 - “DT” Dosing Module - Pellets and Some Regrind
882.01749.00 73 of 93 “DT” Dosing Module - Pellets and Some Regrind
Page 74 - the; plastic; screws to avoid damage to the extruder or
882.01749.00 74 of 93 4-4 Removing/Replacing the Wiper in the “DT” Dosing Station 1. Switch the control unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Empty the dosing station. 4. Open the toggle latches on the dosing motor. 5. Remove the dosing unit from the dosing motor. 6...
Page 75 - -5 Removing the “DT” Disc and cleaning the dosing station; Empty the dosing station.
882.01749.00 75 of 93 4-5 Removing the “DT” Disc and cleaning the dosing station 1. Switch the control unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches. 2. Remove the dosing hopper (D) from the motor. 3. Empty the dosing station. 4. Open the profile cla...
Page 76 - “DP” Powder Dosing Module
Page 77 - Removing/Replacing the “DT” Disc & Cleaning the Dosing Station
882.01749.00 77 of 93 4-6 Removing/Replacing the “DT” Disc & Cleaning the Dosing Station 1. Switch the control unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Empty the dosing station. 4. Open the toggle latches on the dosing motor. 5. Remove the dosing unit from the dosi...
Page 78 - -7 Removing the “DP” Disc and Cleaning the Dosing Station
882.01749.00 78 of 93 4-7 Removing the “DP” Disc and Cleaning the Dosing Station 1. Turn the control unit “Off”. 2. Disconnect the power supply. 3. Open the toggle latches. 4. Remove the dosing hopper (D). 5. Empty the dosing station. 6. Remove the profile clamp (C). 7. Remove the dosing hopper asse...
Page 79 - -8 Exchangeable Dosing Modules; preliminary; DD Discs
882.01749.00 79 of 93 4-8 Exchangeable Dosing Modules Dosing discs of the same type, i.e. “DD” may be exchanged for each other. (The 72 pocket also requires a different shear plate.) If dosing discs with a different compartment number are installed, the new calibration number needs to be entered int...
Page 80 - Parts
882.01749.00 80 of 93 4-9 Spare Parts DD Dosing Units ITEM PART NO QTY U/M DESCRIPTION 1 CT18431 1 EA CALIBRATION BOX CDD CB/SB FIN 2 CT13007 1 EA DISC HSG DD30 MACH & HARDCOAT 3 CT13008 1 EA DRIVE CALIBRATION BOX CDD 4 CT66113 2 EA HOOK FOR DESTACO CLAMP 5 CT18444 2 EA COVER CALIBRATION BOX CDK...
Page 81 - DT Dosing Units
882.01749.00 81 of 93 DT Dosing Units ITEM PART NO QTY U/M DESCRIPTION 1 CT66122 1 EA DISC HOUSING DT30 10MM 2 CT66113 2 EA HOOK FOR DESTACO CLAMP 3 CT99113 1 EA BEARING 6010 2RSR 4 CT23056 1 EA DISC DT30, 20 POCKET 5 CT04294 1 EA COUPLING DRIVE CBQ/SB 6 CT92228 1 EA V-CLAMP DT30 DISC/INTERMEDIATE 7...
Page 82 - DP Dosing Units
882.01749.00 82 of 93 DP Dosing Units ITEM PART NO QTY U/M DESCRIPTION 1 882.00569.00 1 EA DISK, HSG, TIGHT TOL, DP30 2 CT66113 2 EA HOOK FOR DESTACO CLAMP 3 CT99113 2 EA BEARING 6010 2RSR 4 CT99114 2 EA RETAINING RING 80X2.5 5 CT66298 1 EA DISC METERING DP30-5 NYLON 6 CT66109 1 EA HUB K1DP DISK KCT...
Page 83 - DD/DT/DP
882.01749.00 83 of 93 DD/DT/DP Additional Spare Parts ITEM PART NO QTY U/M DESCRIPTION 1 892.01046.00 1 EA COVER WITH KNOB, SS FOR ACRYLIC HOPPER 2 832.00040.00 1 EA ACRYLIC HOPPER, 4.4 LITER, ACRYLIC ONLY 3 832.00041.00 1 EA ACRYLIC HOPPER, 8.8 LITER, ACRYLIC ONLY 4 892.01490.00 1 EA KIT, HANDLE, D...
Page 84 - Appendix A Basic Parameter Settings; A-2 Recipe Formulas; Injection Molding; limitations are listed in the table following the recipe.; Recipe Limitations Extrusion
882.01749.00 84 of 93 Appendix A Basic Parameter Settings A-2 Recipe Formulas The following formulas can be used to determine if a recipe is appropriate or possible. Injection Molding For injection molding applications, compute the dosing disc speed and total number of disc revolutions using the fol...
Page 85 - Appendix B Disc Sizing Guides
882.01749.00 85 of 93 Appendix B Disc Sizing Guides Disc Disc Nomenclature Min/Max Disc RPM Amount of Material Dispensed every Disc Revolution* Minimum Throughput - Continuous Running* Maximum Throughput - Continuous Running* 35 lbs./ft 3 44 lbs./ft 3 35 lbs./ft 3 44 lbs./ft 3 35 lbs./ft 3 44 lbs./f...
Page 87 - Appendix C Drawings; Single Station Digital Dosing Feeder
882.01749.00 87 of 93 Appendix C Drawings Single Station Digital Dosing Feeder SIDE VIEW TOP VIEW
Page 88 - “Duo” Digital Dosing Feeder
882.01749.00 88 of 93 “Duo” Digital Dosing Feeder SIDE VIEW TOP VIEW
Page 89 - Electrical Schematics of A250 Controller
882.01749.00 89 of 93 Electrical Schematics of A250 Controller
Page 91 - Appendix D Spare Parts List; Dosing Disc/Shear Order Numbers; Dosing disc; Replacement Motor Assembly Part Numbers; Gear Motor Assemblies
882.01749.00 91 of 93 Appendix D Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers CT100562 40 chambers CT21710 25 chambers CT21711 18 chambers CT2057 Dosing disc, wear-resistant 40 chambers CT28214 25 chambers CT27141 18 chambers CT27142 Shear for DD style feeder 18, 25 and 4...
Page 92 - Appendix E Technical Assistance; Street
882.01749.00 92 of 93 Appendix E Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which...
