Digital Dosing Disc Additive Feeders Single, Duo and Trio With A250 Controller Part Number: 882.01749.00 Bulletin Number: BF3-600.
Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. ____________ © Copyright 2011 All rights reserved. 882.01749.
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 Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..................................................................... 6 General Safety Regulations ........................................................................................ 7 Responsibility .................................
APPENDIX A BASIC PARAMETER SETTINGS ...................... 84 Injection Molding .................................................................................................................. 84 Extrusion - Simple ................................................................................................................ 84 APPENDIX B DISC SIZING GUIDES ......................................... 85 APPENDIX C DRAWINGS ........................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and safety features.
1-2 General Safety Regulations These regulations should be read, understood and periodically reviewed by all personnel involved in any way with this machine. Never operate or remove any machine components that are secured by wrench-type fasteners unless the motor is electrically locked out and the disc is motionless. Never operate the machine unless the dosing module is in place and all guards and covers are in place and secure.
1-4 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, NEPA or CE and any other local, national and international regulations.
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 systems. The Digital Dosing feeder can meter pellets, micro pellets, prill, powder and granular material of various sizes, when equipped with the appropriate dosing module.
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, monitor, and stop the dosing (feeding) process. Enter, recall, and run recipes. Troubleshoot problems via touch screen. A touch screen is used to enter, modify, and display data.
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 for damage and notify carrier immediately – DO NOT ACCEPT EQUIPMENT IF PACKAGING IS DAMAGED! 2. File a claim with the shipping company immediately if damage is evident. 3.
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 installed on the same terminals (instead of a dry contact.) if the feeder is to be started and stopped through the feeder controller, and not with the extruder screw. 7.
Encoder pulses per disk revolution. See table. Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 Motor and alarm utilty selection Drive tuning. Perform drive tuning. See section # for details. Speed Alarm setup. Select alarm option – Alarm & stop, alarm only, or no alarm. 882.01749.
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 alarm & stop. 882.01749.
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) 2) 3) 4) Additive % Shot Size Screw Recovery Time. Calibration weight. In addition, for the greatest accuracy, samples of the additive should be weighed and entered. Additive % The % additive specifies the proportion of additive to virgin material as a percentage of throughput.
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 operation. The estimated time must be at least ½ of the actual recovery time. If less than ½, the feeder will interpret the recovery signal as a purge cycle. Calibration weight.
“DT” Pellet & Regrind Discs Disc Disc Thickness Calibration No. of Number Pockets 32.00 20 DT 30-101820 10 mm 20mm “DP” Powder Discs Disc DT 30-102025 (“Sure-shot” - 20 20 Oval Calibration Disc Number Thickness DP 30050940 oval holes) 38.00 DT 30-203012 100.00 12 DP 30- DT 30-204010 175.00 10 250940 5mm 17.00 8.00 2.5mm Additive Sample weighing. Weighing samples of additive provides for more precise control of feed rate. Up to 5 samples can be weighed.
Maximum Motor speed. Enter motor RPM. Encoder pulses per disk revolution. See table. Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 Motor and alarm utilty selection 882.01749.
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 your facility. Additive sensor. Select the no sensor, alarm only, or alarm & stop. 882.01749.
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 entered: 1) Additive % 2) Throughput 3) Calibration weight. In addition, for the greatest accuracy, samples of the additive should be weighed and entered.
Throughput. Press throughput specifies the total weight of material through the extruder per minute. The value can be entered in grams, kilograms, ounces, or pounds per minute. The unit of measure is changed by pressing the units button at the middle right of the screen. Changing the unit of measure will NOT change the value displayed on the screen. It is important that this value be adjusted whenever the extruder speed changes. Calibration weight.
“DT” Pellet & Regrind Discs Disc Disc Thickness DT 30-101820 10 mm 20mm Calibration No. of Number Pockets 32.00 20 “DP” Powder Discs Disc DT 30-102025 (“Sure-shot” - 20 20 Oval oval holes) 38.00 DT 30-203012 100.00 12 DT 30-204010 175.00 10 Calibration Disc Number Thickness DP 30-050940 5mm 17.00 DP 30-250940 8.00 2.5mm Feeder Configuration – Extrusion follower: Touch the ACS logo on the main menu screen to access the configuration menu. See section # for details.
Enter/Read Minimum press signal. See section # for details. Enter/Read Maximum press signal. See section # for details. Maximum Motor speed Enter motor speed. Encoder pulses per disk revolution. See table. Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 882.01749.
Motor and alarm utilty selection 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 your facility. 882.01749.
Additive sensor. Select the no sensor, alarm only, or alarm & stop. Virgin material sensor. Select the no sensor, alarm only, or alarm & stop. Recipe Setup for Simple Extrusion: 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) Throughput 3) Throughput RPM 4) Calibration weight. In addition, for the greatest accuracy, samples of the additive should be weighed and entered.
Throughput. Press throughput specifies the total weight of material through the extruder per minute. The value can be entered in grams, kilograms, ounces, or pounds per minute. The unit of measure is changed by pressing the units button at the middle right of the screen. Changing the unit of measure will NOT change the value displayed on the screen. This value is the throughput corresponding to a specific extruder RPM, which will be entered on the following screen.
initially displayed is the weight which would result in a motor speed of 25%. The valid range of values would then be ¼ to 2.5 times this initial value. “DD” Pellet Discs Disc Calibration Number No. of Pockets Disc Thickness DD 30-030672 1.75 72 3 mm DD 30-051040 5.00 40 DD 30-051725 8.00 25 DD 30-051818 15.00 18 5mm “DT” Pellet & Regrind Discs Disc Disc Thickness DT 30-101820 10 mm 20mm Calibration No. of Number Pockets 32.
Press the “Menu” button to skip the weighing procedure and use the calibration weight for feed rate calculations. Note that using the calibration weight is not as accurate as weighing samples. Pressing the “Next” button displays screen #1. Screen 1. Initial preparation for weighing samples. The access cover to the calibration chamber should be removed / opened. The container used to catch and hold the samples should be tared (place the container on the scale and zero the scale).
Screen 4. The disc will make one complete revolution, dispensing additive into the tray. Motor speed is 25%. When the motor stops, Screen 5 is displayed. Screen 5. Weigh the sample, making note of the weight for entry on the next screen. Discard sample & replace tray in calibration box. Press “Next” to display Screen 6. Screen 6. Enter the sample weight obtained from the previous cycle of the feeder. The unit of measure will be the same as used for the calibration weight.
Screen 7. The screen displays the running average of sample weights, as well as the number of samples taken. Pressing “Next” will repeat the process at Screen 4 if less than 5 samples have been taken, otherwise Screen 8 will be displayed. 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.
Chapter 3: Installation and Operation 3-1 Installation Hopper Piece Processing Machine Direction of Material Flow Figure 4. Digital Dosing Feeder Assembly 1. The Digital Dosing additive feeder is not affected by machine vibration, so the best performance is achieved by mounting the feeder directly on the feed throat of the molding machine or extruder (see Figure 4). The inlet into the process machine must be greater than 2” diameter, or an adapter may be necessary.
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 Non-free flowing virgin material, i.e. powder o Consult factory for any special requirements. 3. Optimum mounting of the Digital Dosing feeder is shown in Figure 4, with the additive being dosed in the first few flights of the feed screw.
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: Wire the “cycle/run” cable to the extruder signal output that is proportional to the extruder speed. The signal can be 0-10 VDC or 0-20 mA or 4-20 mA.
3-2 Initial Operation The control system is factory-programmed. However, specific values need to be verified prior to operation (basic parameter settings). The input values will be saved and still be available if the feeder is switched off, or a power failure occurs. Please refer to Appendix B for these values. Extrusion operations require a “span factor” to be entered into the basic settings. These are also explained in Appendix B.
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 the 1st recipe entry/editing screen. Pressing the Edit Recipe button will display the 1st recipe entry/edit screen. See following section. Pressing the New Recipe button will display the New Recipe menu.
Enter / Edit Recipes. Injection molding. In order to calculate the correct motor speed required to feed the desired amount of additive, the following data must be entered: 5) 6) 7) 8) Additive % Shot Size Screw Recovery Time. Calibration weight. In addition, for the greatest accuracy, samples of the additive should be weighed and entered. Additive % The % additive specifies the proportion of additive to virgin material as a percentage of throughput. For example, if the shot size is 200 grams and 8.
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 operation. The estimated time must be at least ½ of the actual recovery time. If less than ½, the feeder will interpret the recovery signal as a purge cycle. Calibration weight. Calibration weight is determined from chart 5.
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 be weighed and entered. Additive % The % additive specifies the proportion of additive to virgin material as a percentage of throughput. For example, if the throughput is 200 grams per minute and 8.
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 for recipe validation and feed rate calculation. If samples are not weighed as described in the next section, this value is used during operation. The weight can be entered in ounces or grams.
The % additive specifies the proportion of additive to virgin material as a percentage of throughput. For example, if the throughput is 200 grams per minute and 8.5 grams of additive are required, the additive percentage would be 4.25. After the additive value has been entered, press the “Next” button to navigate to the Throughput screen. Throughput. Press throughput specifies the total weight of material through the extruder per minute.
Calibration weight is determined from chart 5.1, and is dependant on the disc installed in the feeder. This weight is the amount of standard density material dispensed by the feeder during one revolution of the disc. This weight is used as the initial value for recipe validation and feed rate calculation. If samples are not weighed as described in the next section, this value is used during operation. The weight can be entered in ounces or grams.
Screen 2. The disc will make one complete revolution, insuring all pockets are filled with additive material prior to actual weighing. Motor speed is 25%. Screen 3. When the motor stops, screen 3 is displayed. Discard sample and replace container in calibration box. Press “Next” starts the motor and displays Screen 4. Screen 4. The disc will make one complete revolution, dispensing additive into the tray. Motor speed is 25%. When the motor stops, Screen 5 is displayed. 882.01749.
Screen 5. Weigh the sample, making note of the weight for entry on the next screen. Discard sample & replace tray in calibration box. Press “Next” to display Screen 6. Screen 6. Enter the sample weight obtained from the previous cycle of the feeder. The unit of measure will be the same as used for the calibration weight. Pressing the Enter symbol on the screen keypad displays Screen 7. Screen 7. The screen displays the running average of sample weights, as well as the number of samples taken.
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, if any, are used to calculate the average weight. If no sample weights are entered, the calibration weight is used for calculations. Using less than 5 samples may affect feeder accuracy.
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 screen Throughput screen Motor Speed screen When the A250 is stopped, a 4th screen is available – The Manual Run / Jog screen. Press the Menu button to display the Main Menu screen. 882.01749.
Speed Status Indicator If the speed alarm only option is selected in the configuration section, the following indicators are enabled. Displays when the feeder speed exceeds the calculated speed by greater than that specified on the speed alarm setup screen. The screen will change to a steady orange color. Displayed when the feeder speed is less than that specified on the speed alarm setup screen. The screen will change to a steady orange color.
Totalizer Screen Displays total additive dosed since: A. Or B. Recipe change. Modifying the current recipe will not reset the total. 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 additive is measured in ounces or pounds. Pressing the reset button resets the total display to zero. Throughput Screen Displays the calculated throughput. Injection Press.
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 screen is only available when the A250 control is stopped. This screen provides the means to purge / clear additive, prime additive, etc.. The speed at which the motor will run, jog, or purge.
Pressing and holding the Jog button will run the motor at the indicated speed for as long as the button is held. The length of time the motor will run when the Run Motor button is pressed. Adjustable from 0 to 999 seconds. The default is 0 seconds. Pressing the Run Motor button causes the motor to run for the indicated time. While the motor is running, it can be stopped by pressing the Stop Motor button.
A) B) C) D) The Main Menu, using the Menu button. The System Setup Menu, using the Done button. The next Configuration screen, using the Next button. The previous Configuration screen, using the Prev button. System Setup Navigation Buttons. Navigates to the previous screen in the setup “chain”. See Table 4.1. Navigates to the next screen in the setup “chain”. See Table 4.1. Navigates to the Setup Menu screen. Navigates to the Main Menu screen.
Table 4.1 Injection Press Screen # 60 Title/Function Press Type Prev Screen N/A Next Screen Max Motor Speed 61 Max Motor Speed Press Type 62 Max Motor Speed 64 Encoder Pulses Tune & Speed alarm Default Add. Measure Default Shot Measure Encoder Pulses Tune & Speed alarm 6A 6B 6C 6D 6E Additive Sensor Virgin Sensor Passwords Digital I/O Monitor Analog I/O Monitor 76 Encoder Pulses Tune & Speed alarm Default Add.
61 Max Motor Speed Press Type 62 Max Motor Speed 65 Encoder Pulses Tune & Speed alarm Default Add. Measure Default Thruput Meas. 6A 6B 66 67 68 6C 6D 6E Additive Sensor Virgin Sensor Press Signal Type Min Signal set Max Signal set Passwords Digital I/O Monitor Analog I/O Monitor 76 63 882.01749.00 Encoder Pulses Tune & Speed alarm Default Add. Measure Default Thruput Meas.
Feeder Type. Feeder type is selected by pressing the button in the upper-right corner. The button text changes with each press of the button in the following order: (Default Mode) An injection molding press provides a contact closure during the “Screw Recovery Cycle”, or that period when the press is loading material prior to injection into the mold cavity. The 2 types of extrusion presses are dependant on the input signal provided to the A250 additive feeder.
Maximum Motor Speed. The maximum motor RPM is the maximum rated speed for the motor being used with the A250 control. The default nominal value is 11.5 RPM. This value should be changed to reflect the actual motor RPM based on motor type and tuning results (See Drive Tuning following this section). Initially, this value should be set to the nameplate RPM for the motor/gearbox being used, before proceeding to Drive Tuning. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Turn the Accel & Decel pots fully counter-clockwise.
Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 Motor and alarm utilty selection The Speed Alarm settings screen can be activated by pressing the “Speed Alarm” button. The Drive Tuning screen can be activated by pressing the “Tune Drive” button. See the following sections for these screens. 882.01749.
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 controller. Pressing the “Stop” button (or leaving this screen) will terminate any signal sent to the controller. The numbers on the left are the target min/max values. The numbers on the right are the actual speed values.
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 allows selection of the most commonly used unit of measure. Press the upper right corner to select: Grams Or Ounces 882.01749.
Default Shot Size / Throughput Measure. Injection Press. Extrusion Press This screen sets the default measure for overall weight in recipes. While the measure can be changed in any recipe, this screen allows selection of the most commonly used unit of measure. Press the upper right corner to select: Grams Kilograms Ounces Pounds 882.01749.
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 sensor is present. (Default) Sensor is present. Display alarm screen & activate alarm output, but keep feeder running. Sensor is present. Display alarm screen & activate alarm output, and stop feeder operation. 882.01749.
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 20 mA (milliamps) DC. Minimum Press Signal. (Extrusion Follower only) This screen configures the minimum speed of the press and the analog signal associated with that speed.
This screen configures the maximum speed of the press and the analog signal associated with that speed. Press the top number to enter the maximum speed, using the screen keyboard, in RPM for the press. The voltage associated with that speed can either be entered manually by pressing the value and entering the value on the keyboard, or by pressing the number at the lower left to read the voltage level currently being sent by the press.
Table 4.2 Password requirements. Recipe Functions System Start/Stop Manual Jog/Run System Setup No Passwords Set X X X X Operator Only Active O O O O X - None O - Operator S - Setup Setup Only Active X X X S Operator and. Setup Active O O O S Digital I/O Monitor. This screen monitors the PLC inputs and outputs. When an input or output is on, the indicator is displayed white on black - . When an input or output is off, the indicator is displayed as black on white - ..
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 & move the encoder signal wire from input 0 to any of inputs 1, 2, or 3. Restore power, navigate back to this screen, and change the “ENC CH” # to match the PLC input chosen.
LED Yellow (Station) on: Station Filled off: Station Emptied LED Green (Level Probe) on: Power Supply Available off: Power Supply Not Available npn: Normally Closed pnp: Normally Open 1 npn: Normally Open 0 pnp: Normally Closed Blind Lid Trim-pot with Plastic Screw M3 Protective Screw Cable Level Probe Figure 7. Level Sensor Adjustment Screw 4. Turn the trim-pot until the yellow control lamp just switches off.
Communication Protocol Interfaces The Digital Dosing feeder can be controlled remotely through ODBUS RTU protocol. Contact the Sales Department at 810.720.7300 for more information. OPTIONAL Additive Hoppers Various styles of additive hoppers and options are also available for the Digital Dosing feeder. Contact the Sales Department at 810.720.7300 for more information. 882.01749.
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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. 882.01749.
Chapter 4: Maintenance 4-1 Preventative Maintenance Intervals Check warning signs on equipment for good legibility and Daily: completeness. Check function of the “On/Off” Switch. Weekly: Check shear plate and mounting hardware in “DD” dosing station. Every 3 months: Check wiper and mounting hardware in “DT” dosing station. Check that all electrical and mechanical connections are Every 6 months: tight. Annually: Check dosing disc in dosing station DD and DT.
“DD” Dosing Module - Pellets 882.01749.
4-2 Removing the Shear Plate (“DD dosing Module) Removing the shear 1. Turn “Off” off the “On/Off” switch. Figure 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. Open the profile clamp (B) on the dosing hopper. 7. Remove the dosing hopper from the dosing feeder. 8. Loosen the two screws (C) on the underside of the dosing unit housing (E). 9. Remove the shear (A). Installing the shear 1.
4-3 Removing the “DD” Disc and Cleaning the Dosing Module Dismantling the Dosing Module 1. Switch the control unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches on the dosing motor. 4. Remove the dosing unit from the dosing motor. 5. Empty the dosing module. 6. Open the profile clamp on the dosing hopper. 7. Remove the dosing hopper from the dosing module. 8. Dismantle the dosing module and remove the shear (D) as described above in 5.2. 9.
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 screw to prevent pellets from getting stuck in the hole. 5. Install the shear, verifying that the fasteners are tight. 6. Turn the dosing disc to verify smooth rotation.
“DT” Dosing Module - Pellets and Some Regrind 882.01749.
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. Open the profile clamp (C) of the dosing container. 7. Remove the profile clamp (C). 8. Remove the dosing module (A and B). 9. Loosen the 3 plastic screws on the wiper. 10. Remove the wiper and holding plate. 11.
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 clamp (C). 6. Remove the profile clamp (C). 7. Remove the dosing hopper assembly (A and B). 6. 7. Remove the two M6 x 30 socket screws (B) on top of the dosing disc (A). Lift the dosing disc (A) from the dosing unit housing. 8.
“DP” Powder Dosing Module 882.01749.
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 dosing motor. 6. Open the profile clamp (C) of the dosing container. 7. Remove the profile clamp (C). 8. Remove the dosing module (A and B). 9. Hold disc and rotate the wiper 10. counterclockwise (looking at the disc from the top). 11.
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 assembly (A and B). 8. Remove the wiper and traverse as described above. 9. Remove the four screws from the metering disc and lift the disc from the dosing unit housing. 10. Clean the components with a cotton cloth.
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 into the controller! 2. Enter the preliminary calibration value of the new dosing disc or module. 3. Repeat the “Calibration” procedure to determine the final calibration value.
4-9 Spare Parts DD Dosing Units ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO CT18431 CT13007 CT13008 CT66113 CT18444 CT66861 CT21392 CT92228 CT21710 CT100029.116 CT100023.172 CT100023.145 CT10023.145 CT100023.177 CT88057 CT100023.154 CT100036.105 CT100562 CT21711 CT123057 CT100875 CT66864 CT21392 882.01749.
DT Dosing Units ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO CT66122 CT66113 CT99113 CT23056 CT04294 CT92228 CT99144 CT100029.116 CT11863 CT100031.147 CT100034.147 CT100023.154 CT100034.105 CT11864 CT66707 CT23060 CT18405 CT100031.149 CT66121 882.01749.
DP Dosing Units ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 PART NO 882.00569.00 CT66113 CT99113 CT99114 CT66298 CT66109 882.00570.00 CT99101 CT99102 882.000571.00 CT00879 CT66290 CT66295 CT99325 CT66460 CT1000029.11 CT100023.174 CT100139.132 CT184.30 CT99327 CT66861 CT18444 CT100023.172 CT100023.145 CT00641 CT25013 CT25014 CT25015 882.00593.00 CT66853 CT66296 CT66864 882.01749.
DD/DT/DP Additional Spare Parts ITEM 1 2 3 4 5 6 7 8 9 10 11 PART NO 892.01046.00 832.00040.00 832.00041.00 892.01490.00 CT92228 CT66113 CT99063 CT34299 CT102241 CT34300 892.02095.00 882.01749.00 QTY 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA U/M DESCRIPTION COVER WITH KNOB, SS FOR ACRYLIC HOPPER ACRYLIC HOPPER, 4.4 LITER, ACRYLIC ONLY ACRYLIC HOPPER, 8.
Appendix A Basic Parameter Settings A-2 Recipe Formulas The following formulas can be used to determine if a recipe is appropriate or possible. Injection Molding For injection molding applications, compute the dosing disc speed and total number of disc revolutions using the following formulas. Recipe limitations are listed in the table following the equations. Recipe Limitations for Injection Molding Motor Speed (rpm) Maximum Max Speed (rpm) 3 8.4 11.5 38 3 8.4 11.5 38 Min Speed (rpm) 0.15 0.4 0.6 1.
Appendix B Disc Sizing Guides Disc Nomenclature Disc DD30-030672 P030672 3 mm thick 5.7 mm diameter 72 pockets Default calibration # 1.50 g/rev CT100562 DD30-050660 P050660 5 mm thick 5.7 mm diameter 60 pockets Default Calibration # 822.00738.00 1.30 g/rev DD30-051040 051040 5 mm thick 10 mm dia. 40 pockets Default calibration # 4.00 g/rev CT21710 Min/Max Disc RPM 0.2 RPM 3 RPM 0.2 RPM 8.4 RPM 0.5 RPM 11.5 RPM 1.0 RPM 38 RPM See Note 4 0.2 RPM 3 RPM 0.2 RPM 8.4 RPM 0.5 RPM 11.5 RPM 1.
Disc Disc Nomenclature Min/Max Disc RPM Amount of Material Dispensed every Disc Revolution* 35 lbs./ft3 DT30 101820 Default calibration # 28.00 g/rev DT30-102520 “Sure-shot” 101820 10 mm thick 18 mm dia. 20 holes CT23056 P102520 10 mm thick Oval Hole 18mm x 25mm 20 holes Default calibration # 33.00 g/rev DT30-203012 Default calibration # 95.00 g/rev DT30204010F CT66707 203012 20 mm thick 30 mm dia 12 holes CT23060 204010F 20 mm thick 40 mm dia 10 pockets Default calibration # 150.
Appendix C Drawings Single Station Digital Dosing Feeder SIDE VIEW 882.01749.
“Duo” Digital Dosing Feeder SIDE VIEW TOP VIEW 882.01749.
Electrical Schematics of A250 Controller 882.01749.
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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 40 pocket disc CT21392 72 pocket disc CT100875 Replacement Motor Assembly Part Numbers Gear Motor Assemblies Bauer Bodine N/A 3 RPM 892.02095.00 6.4 RPM 8.4 RPM CT34300 11.5 RPM 11.5 RPM CT102241 35.
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 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.
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