Digital Dosing Disc
Additive Feeders
Single, Duo and Trio
With A250 Controller
Part Number: 882.01749.00
Bulletin Number: BF3-600.5
Effective: 12/17/10
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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.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
; Granulator
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, please contact the parts and service department
at: 262-641-8610. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
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Table of Contents
CHAPTER 1: SAFETY................................................................6
1-1
How to Use This Manual .............................................................................................6
Safety Symbols Used in this Manual.....................................................................6
General Safety Regulations ........................................................................................7
Responsibility ..............................................................................................................7
Warnings and Precautions ..........................................................................................8
1-2
1-3
1-4
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................9
2-1
2-1
2-2
Introduction..................................................................................................................9
A250 Controller .........................................................................................................10
Quick Start-Up Guide ................................................................................................11
Unpacking: ..........................................................................................................11
Mounting:.............................................................................................................11
Feeder Configuration - Injection Molding:............................................................12
Recipe Setup - Injection Molding:........................................................................15
Feeder Configuration – Simple extrusion:...........................................................17
Feeder Configuration – Extrusion follower: .........................................................22
CHAPTER 3: INSTALLATION AND OPERATION ..................31
3-1
3-2
3-3
3-4
3-5
3-6
Installation .................................................................................................................31
Initial Operation .........................................................................................................34
Recipes .....................................................................................................................35
Calibration .................................................................................................................41
Status screens...........................................................................................................44
Optional Features......................................................................................................63
Level switches (probes) .......................................................................................................63
Communication Protocol Interfaces.....................................................................................65
OPTIONAL Additive Hoppers ..............................................................................................65
Virgin Material Supply Hoppers ...........................................................................................67
CHAPTER 4: MAINTENANCE .................................................68
4-1
4-2
Preventative Maintenance Intervals ..........................................................................68
Removing the Shear Plate (“DD dosing Module) ......................................................70
Removing the shear.............................................................................................................70
Installing the shear...............................................................................................................70
4-3
Removing the “DD” Disc and Cleaning the Dosing Module ......................................71
Dismantling the Dosing Module ...........................................................................................71
Installing the Dosing Module................................................................................................72
Installing Different Types of Dosing Discs ...........................................................................72
4-4
4-5
4-6
4-7
4-8
4-9
Removing/Replacing the Wiper in the “DT” Dosing Station ......................................74
Removing the “DT” Disc and cleaning the dosing station .........................................75
Removing/Replacing the “DT” Disc & Cleaning the Dosing Station..........................77
Removing the “DP” Disc and Cleaning the Dosing Station .......................................78
Exchangeable Dosing Modules.................................................................................79
Spare Parts ...............................................................................................................80
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APPENDIX A BASIC PARAMETER SETTINGS ......................84
Injection Molding..................................................................................................................84
Extrusion - Simple................................................................................................................84
APPENDIX B DISC SIZING GUIDES.........................................85
APPENDIX C DRAWINGS ........................................................87
APPENDIX D SPARE PARTS LIST...........................................91
APPENDIX E TECHNICAL ASSISTANCE ................................92
Parts Department ................................................................................................92
Service Department.............................................................................................92
Sales Department................................................................................................92
Contract Department...........................................................................................92
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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. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation. These instructions
are intended to supplement standard shop procedures performed at shift, daily, and weekly
intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your granulator provides excellent, long
term service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or property damage.
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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.
Prior to clearing a jam or performing any maintenance, the motor should be turned off and
electrically locked out. Be sure that the disc has stopped. Hands must not be inserted into the
machine to clear the jam.
Never extend fingers through safety guards.
Be sure that the v-belts are properly aligned and that tension is at its maximum.
Extreme care should be taken to see that all bolts are properly tightened at all times.
This machine is designed for the feeding of free-flowing granular materials. Do not feed any
other materials into the machine without consulting with one of our Application Engineers.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Becoming familiar with materials, inspection, speed limitations, screens, and guard
maintenance and total user responsibility will assist you in learning potential areas in need of
observation for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. All actual or potential
danger areas must be reported to your immediate supervisor.
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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. To
avoid possible personal injury or equipment damage when installing, operating, or maintaining this
equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become damaged or
unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Keep fingers away from rotating discs, slide gates, augers, clean-outs, and calibration
hatches. Automatic operation may start unexpectedly, A PINCH HAZARD
CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE
POWER IS ON.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power and compressed air before servicing or maintaining
the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; NEVER PUT FINGERS OR TOOLS IN HOPPER, AUGER OR SLIDE GATE
AREA.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
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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.
It can be used on extruders, and blow molding and injection molding machines. Single or Dual
Station feeders are the most popular, but three and four component models are also available. See
Figures 1 and 2. This manual covers the installation and operation of all of these feeders.
Figure 1. Single Station Digital Dosing Feeder and A250 Controller
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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.
The control system is switched “On” (position “1") with the “On/Off” switch.
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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. Unpack box, making sure all parts indicated on packing list are included.
4. Check all parts and equipment for any damage sustained during shipment.
5. If any damage is noted, contact manufacturer for replacement or service.
6. Make sure the following are present before proceeding:
; Power: 110 or 220 volt, single phase, 50 or 60 hertz (verify voltage on S/N tag)
; Proper mounting flange adapter, and mounting hardware, for the feed throat
; Dry (ZERO VOLTAGE) contact that closes during screw recovery of IMM
; Gram scale to measure weight of additive material for calibration.
Mounting:
1. Mount the feeder, including the dosing hopper, on the feed throat (may need an adapter).
Be sure to use appropriate fasteners to secure the feeder in place.
2. Connect the motor drive connector (“Amp” connector-black) to the motor.
3. Connect the communication cable (DB-9 plug-silver) to the DB-9 connector on the motor
junction box.
4. Plug power cord into appropriate outlet.
5. INJECTION MOLDING: Connect the “cycle/run” cable (2-conductor - gray) to a dry
(ZERO VOLTAGE) contact that closes during the recovery cycle of the machine. (The
connection in the controller should be on terminal block #10 and PLC input X5.
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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. EXTRUSION – “Follower”: Connect the input cable (2-conductor cable-gray) to a
0-10 VDC, 0-20 mA, or 4-20 mA signal from the extruder
that indicates the screw speed (rpm) of the extruder. (The
connection inside the controller should be on terminals blocks
51and 54.
Feeder Configuration - Injection Molding:
Touch the ACS logo on the main menu screen to access the configuration menu. See section # for
details.
Feeder Type Selection. Select injection molding (default value).
Maximum Motor speed. Enter nominal motor speed.
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Encoder pulses per disk revolution. See table.
Manufacturer
Motor Color
RPM
Encoder Pulses
Bodine
Bodine
Bodine
Bodine
Black & silver
Black & silver
Black & silver
Black & silver
3
8400
8400
5700
1800
8.4
11.5
38
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.
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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.
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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) 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 8.5 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 Shot Size
screen.
Shot Size
The shot size specifies the total capacity of the mold in use on the press. The value can be entered in
grams, kilograms, ounces, or pounds. 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.
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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 the following tables, 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 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. The value
initially displayed is the weight which would result in a motor speed of 25%. The valid range of values would
then be ¼ to 5 times this initial value.
“DD” Pellet Discs
Disc
Calibration Number
No. of Pockets Disc Thickness
DD 30-030672
DD 30-051040
DD 30-051725
DD 30-051818
1.75
5.00
72
40
25
18
3 mm
8.00
5mm
15.00
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“DT” Pellet & Regrind Discs
Disc
Calibration
No. of
Pockets
20
Disc
“DP” Powder Discs
Thickness
Number
Calibration
Disc
DT 30-101820
DT 30-102025
(“Sure-shot” - 20
oval holes)
32.00
Disc
Number
Thickness
10 mm
20mm
DP 30-
20 Oval
5mm
050940
38.00
100.00
175.00
17.00
8.00
DT 30-203012
DT 30-204010
12
10
DP 30-
2.5mm
250940
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 weighing process may be skipped altogether, in which case the
calibration weight is used for calculations of feed rate. See the section Weight Calibration at
the end of this section.
Feeder Configuration – Simple extrusion:
Touch the ACS logo on the main menu screen to access the configuration menu. See section # for
details.
Feeder Type Selection. Select simple extrusion.
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Maximum Motor speed. Enter motor RPM.
Encoder pulses per disk revolution. See table.
Manufacturer
Motor Color
RPM
Encoder Pulses
Bodine
Bodine
Bodine
Bodine
Black & silver
Black & silver
Black & silver
Black & silver
3
8400
8400
5700
1800
8.4
11.5
38
Motor and alarm utilty selection
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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.
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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.
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 8.5 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.
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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.
Calibration weight is determined from the following tables, 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 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. The value
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
DD 30-051040
DD 30-051725
DD 30-051818
1.75
5.00
72
40
25
18
3 mm
8.00
5mm
15.00
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“DT” Pellet & Regrind Discs
Disc
Calibration
No. of
Pockets
20
Disc
“DP” Powder Discs
Thickness
Number
Calibration
Disc
DT 30-101820
DT 30-102025
(“Sure-shot” - 20
oval holes)
32.00
Disc
Number
Thickness
10 mm
20mm
20 Oval
DP 30-050940
5mm
38.00
100.00
175.00
17.00
8.00
DT 30-203012
DT 30-204010
12
10
DP 30-250940
2.5mm
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, 0-10V, 0-20mA, or 4-20mA.
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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
Bodine
Bodine
Bodine
Black & silver
Black & silver
Black & silver
Black & silver
3
8400
8400
5700
1800
8.4
11.5
38
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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.
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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.
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 8.5 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.
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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. Given these reference values, the correct feed rate can be determined for any
extruder speed. Note that the minimum and maximum press speeds and signal levels must be entered correctly
in Setup.
Throughput Speed.
The press speed corresponding to the throughput value entered on the previous screen. Given these
reference values, the correct feed rate can be determined for any extruder speed. Note that the minimum and
maximum press speeds and signal levels must be entered correctly in Setup.
Calibration weight.
Calibration weight is determined from the following tables, 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 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. The value
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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
DD 30-051040
DD 30-051725
DD 30-051818
1.75
5.00
72
40
25
18
3 mm
8.00
5mm
15.00
“DT” Pellet & Regrind Discs
Disc
Disc
Calibration
Number
32.00
No. of
Pockets
20
“DP” Powder Discs
Thickness
Calibration
Disc
DT 30-101820
Disc
Number
Thickness
DT 30-102025
10 mm
(“Sure-shot” - 20
20 Oval
DP 30-050940
5mm
oval holes)
38.00
100.00
175.00
17.00
8.00
DT 30-203012
20mm
12
10
DP 30-250940
2.5mm
DT 30-204010
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 weighing
process may be skipped altogether, in which case the calibration weight is used for calculations of feed rate.
Weight Calibration.
The final step of recipe setup is weight calibration. This procedure is common to all types of presses
supported. After entering the calibration weight, pressing the “Next” button displays the following screen:
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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). The container should then be placed in the calibration chamber. Press “Next” when
these steps have been completed. The motor will begin to run as Screen 2 will be displayed.
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.
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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. Pressing the Enter symbol on the screen keypad displays Screen 7.
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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. 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.
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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. If an adapter is required, it
must be designed so that there are no edges where material can hang up - it must be
smooth to promote consistent material flow.
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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.
4. The controller should be remote mounted for operator convenience. The control unit
must not be exposed to temperatures above 45° C (115° F), or excessive moisture.
5. Electrical connection to process machine:
Injection Molding: Connect the “cycle/run” cable (thin, gray two-conductor
cable) to a set of dry (NO VOLTAGE) contacts that CLOSE
for the duration of the screw recovery. (See Figure 5.)
TB #10
X5
Relay contact
Injection molding
Digital Dosing controller
Figure 5. Electrical Interface Connection Diagram –
Injection Molding or Extrusion - Constant
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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. Jumpers J1
and J2 should be installed for 0-20mA or 4-20mA, and removed for 0-10VDC.
NOTES: 1. Signal voltage from the extruder must to be isolated. Consult factory for
other signal requirements. External signal converter may be required.
2. “Zero” input corresponds to zero screw speed and no additive dosing.
“Maximum” input corresponds to maximum screw speed.
TB #51
TB #54
_
+
0-10 VDC or 0/4-20 mA
Extruder output
Digital Dosing controller
Figure 6. Analog Extruder Input Connection Diagram –
Extrusion - Proportional
.
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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.
Prior to putting your new Digital Dosing feeder on-line:
Configure the feeder control for motor speed, encoder pulses, sensors, and alarm
options.
Tune the drive.
Enter a recipe.
Calibrate the additive weight for best accuracy.
NOTE: Recipe parameters are different for Injection Molding, Extrusion –
Constant, and Extrusion - Proportional operation. See each individual section for
details.
Once the feeder is on-line, recipes can be saved for later recall (up to 50 standard).
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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.
Pressing the Edit Recipe button will display the 1st recipe entry/edit screen. See following section.
Select a new recipe by pressing the recipe # value. Press the “Next Avail” button to use the next available
empty / unused recipe number.
Pressing the Delete Recipe button will display a confirmation screen as follows:
Press the Delete Recipe button to clear all values from the current recipe. Pressing the Keep Recipe
button will retain the values and return to the Recipe Menu screen.
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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) Additive %
6) Shot Size
7) Screw Recovery Time.
8) 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 8.5 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 Shot Size
screen.
Shot Size
The shot size specifies the total capacity of the mold in use on the press. The value can be entered in
grams, kilograms, ounces, or pounds. 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.
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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 5.1, 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 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. The value initially displayed
is the weight which would result in a motor speed of 25%. The valid range of values would then be ¼ to 5
times this initial value.
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 weighing
process may be skipped altogether, in which case the calibration weight is used for calculations of feed rate.
See the section Weight Calibration at the end of this section.
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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 8.5 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. 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.
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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 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. The value 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.
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 weighing
process may be skipped altogether, in which case the calibration weight is used for calculations of feed rate.
See the section Weight Calibration at the end of this section.
Extrusion Follower Recipe.
In order to calculate the correct motor speed required to feed the desired amount of additive, the
following data must be entered:
1) Additive %
5) Throughput
6) Throughput RPM
7) Calibration weight.
In addition, for the greatest accuracy, samples of the additive should be weighed and entered.
Additive %
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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. 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. Given these reference values, the correct feed rate can be determined for any
extruder speed. Note that the minimum and maximum press speeds and signal levels must be entered correctly
in Setup.
Throughput Speed.
The press speed corresponding to the throughput value entered on the previous screen. Given these
reference values, the correct feed rate can be determined for any extruder speed. Note that the minimum and
maximum press speeds and signal levels must be entered correctly in Setup.
Calibration weight.
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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 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. The value 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.
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 weighing
process may be skipped altogether, in which case the calibration weight is used for calculations of feed rate.
3-4 Calibration
The final step of recipe setup is weight calibration. This procedure is common to all types of presses
supported. After entering the calibration weight, pressing the “Next” button displays the following screen:
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). The container should then be placed in the calibration chamber. Press “Next” when
these steps have been completed. The motor will begin to run as Screen 2 will be displayed.
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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.
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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.
Pressing “Next” will repeat the process at Screen 4 if less than 5 samples have been taken, otherwise Screen 8
will be displayed.
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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.
3-5 Status screens
Status Screens
The status screens reflect the state of the feeder during operation. The status screens are accessed by
pressing the “Status” button on the main menu.
Prerequisites.
Before the status screens can be displayed, the current recipe must be valid & complete.If the current
recipe is not valid, an advisory screen is displayed :
Invalid Recipe:
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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.
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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.
Displayed when no encoder pulses are detected from the drive motor. The screen will
change to a steady orange color.
Displayed when the calculated motor speed is greater than the rated motor speed. The
screen will change to orange and flash in this condition.
Displayed when the calculated motor speed is less than 5% of the rated motor speed.
The screen will change to orange and flash in this condition.
Disc Motor Indicator
Displayed when the drive motor is running.
Press Signal Indicator
Displayed when press signal is detected:
Injection – Screw recovery signal.
Simple Extrusion – Press Run signal.
Extrusion Follower – Analog speed signal.
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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. Throughput is based on recipe data and measured average screw recovery time. A running
average of the 5 most recent screw recovery times is used.
Simple extrusion. Throughput is based on recipe data.
Extrusion Follower. Throughput is based on recipe data and the current press speed signal.
Motor Speed Screen
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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. Adjust using the Accel and
Decel buttons.
Pressing and holding either of these buttons will adjust the motor run speed by
approximately 1% of max speed every ½ second. The minimum speed is 5%, while the maximum speed is
100%. The default speed is 50%.
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Pressing and holding the Jog button will run the motor at the indicated speed for as long as the
The length of time the motor will run when the Run Motor button is pressed.
button is held.
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.
Pressing the Purge button will cause the feeder to run at the indicated rate for the duration of
the next screw recovery signal. The purge mode will be cancelled at the end of the screw recovery signal or as
noted below.
Pressing the Purge button when purge mode is active will cancel purge mode.
Configuration.
Navigation.
The top level of System setup navigation is the System Setup Menu:
System Setup Menu
The configuration screens are grouped by similar function. Each of the buttons on the System Setup
Menu screen will navigate to the 1st screen of each group. From each configuration screen, any of the
following screens can be reached:
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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 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.
From the Drive Tuning screen, returns to the Max RPM screen.
From the Speed Alarm screen, returns to the Encoder Pulses screen.
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Table 4.1
Injection Press
Screen
#
60
Title/Function
Press Type
Prev Screen
N/A
Next Screen
Max Motor Speed
61
62
76
63
64
Max Motor Speed
Press Type
Encoder Pulses
Tune & Speed
alarm
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Max Motor Speed
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Default Add. Measure
Default Shot Measure
Additive Sensor
Default Shot
Measure
Default Shot
Measure
Additive Sensor
Virgin Sensor
Passwords
6A
6B
6C
6D
6E
Additive Sensor
Virgin Sensor
Passwords
Digital I/O Monitor
Analog I/O Monitor
Virgin Sensor
Passwords
Digital I/O Monitor
Analog I/O Monitor
Setup Menu
Digital I/O Monitor
Simple Extrusion Press
Screen
#
60
61
Title/Function
Press Type
Max Motor Speed
Prev Screen
N/A
Press Type
Next Screen
Max Motor Speed
Encoder Pulses
Tune & Speed
alarm
62
76
63
65
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Max Motor Speed
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Default Add. Measure
Default Shot Measure
Additive Sensor
Default Thruput
Meas.
Default Thruput
Meas.
Additive Sensor
Virgin Sensor
Passwords
6A
6B
6C
6D
6E
Additive Sensor
Virgin Sensor
Passwords
Digital I/O Monitor
Analog I/O Monitor
Virgin Sensor
Passwords
Digital I/O Monitor
Analog I/O Monitor
Setup Menu
Digital I/O Monitor
Extrusion Follower Press
Screen
#
60
Title/Function
Press Type
Prev Screen
N/A
Next Screen
Max Motor Speed
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61
62
76
63
65
Max Motor Speed
Press Type
Encoder Pulses
Tune & Speed
alarm
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Max Motor Speed
Encoder Pulses
Tune & Speed
alarm
Default Add.
Measure
Default Add. Measure
Default Shot Measure
Additive Sensor
Default Thruput
Meas.
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
Virgin Sensor
Additive Sensor
Virgin Sensor
Press Signal Type
Min Signal set
Max Signal set
Passwords
Press Signal Type
Min Signal set
Max Signal set
Passwords
Digital I/O Monitor
Analog I/O Monitor
Setup Menu
Digital I/O Monitor
Analog I/O Monitor
Digital I/O Monitor
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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. Simple extrusion provides a contact closure to input 5 of the PLC, and it is assumed that the press is
always run at the speed entered for the active recipe. Extrusion follower provides an analog signal to channel 0
of the analog module which changes in relation to the speed (throughput) of the press.
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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) Turn the Accel & Decel pots fully counter-clockwise.
2) Press the “Min” button.
3) Check rotation direction. Disk should turn (counterclockwise).
4) Swap A+ & A- leads With Power Off to change rotation direction.
5) Press “Max” button.
6) Adjust max pot to adjust max speed to match target value.
7) Press “Min” button.
8) Adjust min pot to adjust min speed to match target value.
9) Repeat steps 5-8 until readings stabilize.
10) If maximum speed value cannot be obtained, change max RPM on the Maximum Motor Speed
screen to match the closest value obtained on this screen.
Encoder Pulses.
The encoder pulses are determined by the number of encoder steps per motor revolution (usually 30)
multiplied by the gearbox ratio. In the case of the standard motor, the ratio is 190:1, so 30 X 190 = 5700. To
change the value, press the value on the screen to activate the keyboard. Key in the correct value and press the
key.
Manufacturer
Motor Color
RPM
Encoder Pulses
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Bodine
Bodine
Bodine
Bodine
Black & silver
Black & silver
Black & silver
Black & silver
3
8400
8400
5700
1800
8.4
11.5
38
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.
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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. A small screwdriver, preferably non-metallic, is needed
to tune the drive. Tune the drive as follows:
Speed Alarm
The reaction to deviations from the commanded speed are controlled via this screen. Speed deviation
specifies the window within which the motor speed must be for normal operation. The Alarm Delay specifies
the minimum time the speed must be outside this window before generating an alarm. For example, if the
default values are used and the commanded speed is 5 RPM, the controller will alarm if the speed is less than
4.75 RPM or more than 5.25 RPM for at least 2 seconds. The specific response to the alarm condition can be
selected by pressing the button in the lower left corner as follows:
Take no action. See Status screens for indicator.
Activate alarm screen & alarm output on PLC.
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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
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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
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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.
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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. Press the top number to enter the minimum 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. The unit of measure, A or V, is determined by the selection made on the Press Signal Type screen.
Maximum Press Signal. (Extrusion Follower only)
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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. The unit of measure, A or V, is determined by the selection made on the Press Signal Type screen.
Note: The Minimum & maximum press signal values are used to calculate the relationship between input
signal and extruder speed. Operation at speeds below the minimum and above the maximum are possible,
subject to input signal limits. See appendix # for examples.
Passwords Screen.
The passwords screen allow the entry of Operator & Setup passwords. By default, these are set to 0,
which disables the password requirement. Setting the password to a non-zero value activates password
protection. To set / change the Operator password, press the value next to “Operator” and enter the new
password using the screen keyboard. To change the password duration, press the duration value & enter the
new duration using the screen keyboard. The Setup password and duration are entered in the same way. Refer
to Table 4.2 for password requirements based on which passwords are enabled.
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Table 4.2
Password requirements.
No Passwords
Operator Only
Setup Only
Operator and.
Set
X
Active
Active
Setup Active
Recipe Functions
System Start/Stop
Manual Jog/Run
System Setup
O
O
O
O
X
X
X
S
O
O
O
S
X
X
X
X - None
O - Operator
S - Setup
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 -
..
If using the Modbus communications option, the node (station) number is set here. Valid node
numbers are 0-32.
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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.
When the “Jog Mtr” button is pressed, the motor will run at 25% speed for as long as the button is
pressed. The top line will display the raw encoder value. The “MTR OUT” value will be 500 for KB or Bodine
drives, or 1000 for Dart drives. The “PRESS” value will be 0-4000, depending on the press signal, if no press
signal is connected, the value will be at or near zero.
3-6 Optional Features
Optional equipment for the Digital Dosing Additive Feeder includes:
Loaders
Several versions of automatic loaders are available to keep the additive (or virgin material) supply
hoppers full – consult with your sales contact for the unit that best fits your needs.
Hoppers
Several versions of hoppers are available and can be used in different applications - consult with
your sales contact for the unit that best fits your needs.
Alarms
Several alarm options are available for the Digital Dosing feeder. Options include both audible horns
and flashing lights. An optional no voltage alarm relay can be connected to the user’s central alarm
system.
Level switches (probes)
To adjust the level switches:
1. Turn the controller ON.
2. Fill the dosing station until the level sensor is one-third covered.
3. Remove the plastic screw (M3) on the back of the level sensor (see Figure 7).
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LED Yellow (Station)
on: Station Filled
LED Green (Level Probe)
on: Power Supply Available
off: Power Supply Not Available
off: Station Emptied
npn: Normally Closed
pnp: Normally Open
npn: Normally Open
pnp: Normally Closed
1
0
Blind Lid
Protective Screw
Trim-pot with
Plastic Screw M3
Cable
Level Probe
Figure 7. Level Sensor Adjustment Screw
4. Turn the trim-pot until the yellow control lamp just switches off.
NOTE: Turning the trim-pot to the left decreases the switching sensitivity, and
turning it to the right increases the sensitivity.
5. Fill the dosing station until the level probe is two-thirds covered. The yellow control
lamp should now switch on again. If not, repeat Step 4.
6. Reinstall the plastic screw (M3).
NOTE: The sliding switch under the cover must be set on “0”.
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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.
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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.
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Chapter 4: Maintenance
4-1 Preventative Maintenance Intervals
Check warning signs on equipment for good legibility and
completeness.
Daily:
Check function of the “On/Off” Switch.
Check shear plate and mounting hardware in “DD” dosing
station.
Weekly:
Every 3
months:
Check wiper and mounting hardware in “DT” dosing station.
Check that all electrical and mechanical connections are
tight.
Every 6
months:
Check adjustment of the level probes (optional).
Check dosing disc in dosing station DD and DT.
Clean the dosing station.
Annually:
Each time
after material
Is changed:
Check shear plate or wiper.
Check dosing disc.
CAUTION:
Always disconnect power and remove the dosing
module from the motor assembly before taking the
dosing module apart.
Injury could result if fingers are pinched between
the rotating disc.
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“DD” Dosing Module - Pellets
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4-2 Removing the Shear Plate (“DD dosing Module)
F
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. 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. Place the new shear in the dosing unit housing, and ensure that it is positioned correctly.
2. Bolt the shear in place with the two (2) hexagon M5 x 16 socket screws and lock washers.
3. Turn the dosing disc to verify smooth rotation. Replace shear if it is dragging on disc when disc is
rotated.
4. Position the dosing hopper on the dosing module, and install the profile clamp (B).
5. Tighten the M10 hex head screw on the profile clamp.
6. Position the dosing unit on the dosing motor, aligning the guide pins.
7. Close the toggle latches, fastening the dosing module to the motor assembly.
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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. Loosen and remove the two M6 x 30 socket screws (C) on top of the dosing disc (A).
10. Remove the center M6 x 12 socket screw (B) and replace with an M6 x 30 or 60 screw.
11. Lift the dosing disc (A) from the
dosing unit housing (B) by
tightening this screw.
12. Clean the shear plate with a
cotton cloth.
13. Clean the dosing hopper and the
dosing disc in soapy water.
14. The dosing unit housing may also
be cleaned with a soft cloth,
keeping liquids out of the
bearings.
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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. If the disc drags on the shear, the shear
may have to be loosened and re-positioned, or replaced.
7. Position the hopper on the dosing module.
8. Tighten the profile clamp.
9. Position the dosing unit on the dosing motor, aligning the guide pins.
10. Close the toggle latches, fastening the dosing module to the motor assembly.
Installing Different Types of Dosing Discs
Dosing discs of the same type, and thickness (except 72 pocket), may be exchanged for each other. If
dosing discs with a different compartment number or thickness are installed, the new calibration
number needs to be entered into the controller!
1. Enter the (preliminary) calibration value of the newly installed dosing disc
2. Repeat the “calibration” procedure to determine the final calibration value.
See Appendix D: Spare Parts List on page 61 for disc part numbers.
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“DT” Dosing Module - Pellets and Some Regrind
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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. Install the new wiper along with the holding plate.
12. 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.)
13. Install the dosing hopper on the dosing housing, ensuring the guide pin is in place,
and locate the “shelf” above the module discharge hole.
14. Install and tighten the profile clamp.
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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. Remove the two M6 x 30 socket screws (B)
on top of the dosing disc (A).
7. Lift the dosing disc (A) from the dosing unit
housing.
8. Clean the components with a cotton cloth.
9. Clean the dosing hopper (A and B) in
soapy water.
10. Dry all parts thoroughly.
11. Install the dosing hopper on the dosing
module (locating the guide pin).
12. Install the profile clamp and tighten
the screw.
13. Mount the dosing housing onto the
dosing motor.
14. Close the toggle latches, securing the
dosing module to the motor assembly.
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“DP” Powder Dosing Module
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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. Remove the wiper and “traverse” (holding plate).
12. Install the new wiper along with the “traverse” (holding plate).
13. Rotate the wiper clockwise, while the metering disc in place.
14. Install the dosing hopper on the dosing housing, ensuring the guide pin is in place,
15. and locate the “shelf” above the module discharge hole.
16. Install and tighten the profile clamp
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4-7 Removing the “DP” Disc and Cleaning the Dosing Station
1. Turn the control unit “Off”.
2.
3.
4.
5.
6.
7.
Disconnect the power supply.
Open the toggle latches.
Remove the dosing hopper (D).
Empty the dosing station.
Remove the profile clamp (C).
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.
11. Clean the dosing hopper (A and B) in soapy water.
12. Dry all parts thoroughly.
13. Install the dosing hopper on the dosing module (locating the guide pin).
14. Install the profile clamp and tighten the screw.
15. Mount the dosing housing onto the dosing motor.
16. Close the toggle latches, securing the dosing module to the motor assembly.
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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.
DD Discs
Disc
Calibration
Number
1.75
Number of
pockets
72
DD 30-030672
DD 30-051040
DD 30-051725
DD 30-051818
5.00
40
8.00
25
15.00
18
DT Discs
Calibration
Number
32.00
Disc
Number of
Pockets
DT 30-101820
DT 30-102025
“Sure-shot”
20
38.00
100.00
175.00
20 “Oval”
DT 30-203012
DT 30-204010
12
10
DP Discs
Disc
Calibration
Number
Disc
Number
of
Pockets
40
Thickness
DP 30-050940
17.00
8.00
0.5 mm
2.5 mm
DP 30-250940
40
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4-9 Spare Parts
DD Dosing Units
ITEM PART NO
QTY U/M DESCRIPTION
1
CT18431
CT13007
CT13008
CT66113
CT18444
CT66861
CT21392
CT92228
CT21710
1 EA CALIBRATION BOX CDD CB/SB FIN
1 EA DISC HSG DD30 MACH & HARDCOAT
1 EA DRIVE CALIBRATION BOX CDD
2 EA HOOK FOR DESTACO CLAMP
2 EA COVER CALIBRATION BOX CDK/CDD
2 EA GASKET COVER CAL BOX CDK/CDD
1 EA SHEAR CDD 1.0 CBQ/SB
2
3
4
5
6
7
8
1 EA V-CLAMP DT30 DISC/INTERMEDIATE
1 EA DISC DD30, 40 POCKET
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
CT100029.116 1 EA BEARING DOUBLE ROW CDDd40; D80; B30.2
CT100023.172 4 EA SCREW PAN PHILLIPS M4X12
CT100023.145 4 EA SCREW SOCKET M6X16
CT10023.145
CT100023.177 2 EA SCREW SOCKET M6X30
CT88057 1 EA SCREW, M6X10
4 EA SCREW SOCKET M4X40
CT100023.154 2 EA SCREW SOCKET M5X16
CT100036.105 2 EA WASHER LOCK M5
CT100562
CT21711
CT123057
CT100875
CT66864
CT21392
1 EA DISC DD30, 72 POCKET
1 EA DISC DD30, 25 POCKET
1 EA DISC DD30, 18POCKET
1 EA SHEAR DD, 72 POCKET, 3MM
1 EA TRAY CAL BOX
1 EA ALL OTHER DISCS, 5MM
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DT Dosing Units
ITEM PART NO
QTY
U/M DESCRIPTION
1
2
3
4
5
6
7
CT66122
CT66113
CT99113
CT23056
CT04294
CT92228
CT99144
1 EA DISC HOUSING DT30 10MM
2 EA HOOK FOR DESTACO CLAMP
1 EA BEARING 6010 2RSR
1 EA DISC DT30, 20 POCKET
1 EA COUPLING DRIVE CBQ/SB
1 EA V-CLAMP DT30 DISC/INTERMEDIATE
1 EA RETAINING RING 80X2.5
8
9
CT100029.116 4 EA SCREW PAN PHILLIPS M4X12
CT11863 1 EA MOUNT CALIBRATE TUBE CDK/CB/SB
10
11
12
13
14
15
16
17
18
19
CT100031.147 3 EA SCREW HEX M6X35
CT100034.147 1 EA WASHER FLAT M6
CT100023.154 2 EA SCREW SOCKET M5X16
CT100034.105 2 EA WASHER FLAT M5
CT11864
CT66707
CT23060
CT18405
1 EA CALIBRATION TUBE CDK/CB/SB
1 EA DISC DT30, 20 POCKET, SURE SHOT
1 EA DISC DT30 12 POCKET 20MM DEEP
1 EA DISC DT30 1O POCKET, 20MM DEEP
CT100031.149 2 EA SCREW HEX M6X35
CT66121
1 EA DISC HOUSING DT30 20MM
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DP Dosing Units
ITEM PART NO
QTY U/M DESCRIPTION
1
2
3
882.00569.00
CT66113
CT99113
1 EA DISK, HSG, TIGHT TOL, DP30
2 EA HOOK FOR DESTACO CLAMP
2 EA BEARING 6010 2RSR
4
CT99114
2 EA RETAINING RING 80X2.5
5
6
CT66298
CT66109
1 EA DISC METERING DP30-5 NYLON
1 EA HUB K1DP DISK KCT
7
8
9
882.00570.00
CT99101
CT99102
1 EA TRAVERST, TIGHT TOL 5MM, DP30
2 EA BEARING 626 2RS D6X19X6
2 EA BEARING 6000 2RS 10X26X8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
882.000571.00 1 EA DISK, EJECT, TIGHT TOL, DP30, 5MM
CT00879
CT66290
CT66295
CT99325
CT66460
1 EA BUSHING DISC EJECTION DP30-5
1 EA WIPER BLADE DP30-5
1 EA AGITATOR DP30 W/SAIL
1 EA SEAL V22A DP30/DP50
1 EA COUPLING DRIVE DP30 (E)
CT1000029.11 4 EA SCREW PAN PHILLIPS M4X12
CT100023.174 2 EA SCREW SOCKET M6X20
CT100139.132 4 EA SCREW SOCKET FLAT M6X16
CT184.30
CT99327
CT66861
CT18444
1 EA CALIBRATION BOX DT30/DP30 FIN
1 EA RETAINING RING 50X2
2 EA GASKET COVER CAL BOX CDK/CDD
2 EA COVER CALIBRATION BOX CDK/CDD
CT100023.172 4 EA SCREW SOCKET M6X16
CT100023.145 4 EA SCREW SOCKET M4X40
CT00641
CT25013
CT25014
CT25015
882.00593.00
CT66853
CT66296
CT66864
1 EA WIPER BLADE DP30-2.5
1 EA DISC METERING DP30-2.5 NYLON
1 EA DISK, EJECT, TIGHT TOL, 5MM DP30
1 EA BUSHING DISC EJECTION DP30-5
1 EA TRAVERSE, TIGHT TOL, 5MM, DP30
1 EA DRIVE CALIBRATION BOX CDK
1 EA DP30, STANDARD AGITATOR
1 EA TRAY CAL BOX
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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
3
4
5
6
7
8
9
832.00040.00 1 EA
832.00041.00 1 EA
892.01490.00 1 EA
ACRYLIC HOPPER, 4.4 LITER, ACRYLIC ONLY
ACRYLIC HOPPER, 8.8 LITER, ACRYLIC ONLY
KIT, HANDLE, DD/DT/DP, SUPPLY HOPPER
V-CLAMP DD/DT/TP, HOPPER TO DISK HOUSING
HOOK FOR TOGGLE CLAMP
CT92228
CT66113
CT99063
CT34299
CT102241
CT34300
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA
TOGGLE LATCH
DOSING MOTOR ASSEMBLY,38 RPM
DOSING MOTOR ASSEMBLY, 11.5 RPM
DOSING MOTOR ASSEMBLY, 8.4 RPM
DOSING MOTOR ASSEMBLY, 3 RPM
10
11
892.02095.00 1 EA
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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)
Min Speed (rpm)
3
3
0.15
0.4
0.6
8.4
11.5
38
8.4
11.5
38
1.9
Extrusion - Simple
For extrusion applications, compute the dosing disc speed using the following formula. Recipe
limitations are listed in the table following the recipe.
( Additive - %) x (Total Extruder Throughput - lb / hr)
Disc RPM =
13.22 x (Disc Calibration Weight - g)
Recipe Limitations Extrusion
Motor Speed (rpm)
Maximum
Max Speed (rpm)
Min Speed (rpm)
3
3
0.15
0.4
0.6
8.4
11.5
38
8.4
11.5
38
1.9
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Appendix B Disc Sizing Guides
Disc
Nomenclature
Min/Max
Disc RPM
Amount of Material Dispensed
every Disc Revolution*
Minimum Throughput -
Continuous Running*
Maximum Throughput -
Continuous Running*
Disc
35 lbs./ft3
44 lbs./ft3
35 lbs./ft3
44 lbs./ft3
35 lbs./ft3
44 lbs./ft3
P030672
0.2 RPM
3 RPM
0.04 lbs/hr
0.02 kg/hr
0.04 lbs/hr
0.02 kg/hr
0.61 lbs/hr
0.28 kg/hr
0.77 lbs/hr
0.35 kg/hr
DD30-030672
3 mm thick
5.7 mm diameter
72 pockets
0.2 RPM
8.4 RPM
0.04 lb/hr
0.02 kg/hr
0.04 lb/hr
0.02 kg/hr
1.69 lbs/hr
0.77 kg/hr
2.17 lbs/hr
0.98 kg/hr
1.53 g/rev
0.02 g/hole
1.95 g/rev
0.027 g/hole
0.5 RPM
11.5 RPM
0.10 lb/hr
0.045 kg/hr
0.12 lb/hr
0.05 kg/hr
2.32 lbs/hr
1.05 kg/hr
2.89 lbs/hr
1.31 kg/hr
Default
calibration #
1.50 g/rev
CT100562
(micropellets)
(micropellets)
1.0 RPM
38 RPM
0.19 lb/hr
0.09 kg/hr
0.26 lb/hr
0.12 kg/hr
7.66 lbs/hr
3.47 kg/hr
9.63 lbs/hr
4.37 kg/hr
See Note 4
P050660
0.2 RPM
3 RPM
0.04 lbs/hr
0.02 kg/hr
0.06 lbs/hr
0.03 kg/hr
0.42 lbs/hr
0.19 kg/hr
0.54 lbs/hr
0.24 kg/hr
DD30-050660
5 mm thick
5.7 mm diameter
60 pockets
0.2 RPM
8.4 RPM
0.05 lb/hr
0.02 kg/hr
0.07 lb/hr
0.03 kg/hr
1.1 lbs/hr
0.50 kg/hr
1.37 lbs/hr
0.62 kg/hr
1.35 g/rev
0.02 g/hole
1.70 g/rev
0.028 g/hole
0.5 RPM
11.5 RPM
1.0 RPM
38 RPM
0.09 lb/hr
0.04 kg/hr
0.17 lb/hr
0.08 kg/hr
0.10 lb/hr
0.05 kg/hr
0.22 lb/hr
0.10 kg/hr
1.46 lbs/hr
0.66 kg/hr
6.48 lbs/hr
2.94 kg/hr
1.83 lbs/hr
0.83 kg/hr
8.54 lbs/hr
3.87 kg/hr
Default
Calibration #
1.30 g/rev
822.00738.00
See Note 4
051040
0.2 RPM
3 RPM
0.11 lb/hr
0.05 kg/hr
0.15 lb/hr
0.07 kg/hr
1.68 lbs/hr
0.76 kg/hr
2.14 lbs/hr
0.97 lbs/hr
DD30-051040
5 mm thick
10 mm dia.
40 pockets
0.2 RPM
8.4 RPM
0.11 lb/hr
0.05 kg/hr
0.15 lb/hr
0.07 kg/hr
4.71 lbs/hr
2.12 kg/hr
5.99 lbs/hr
2.72 kg/hr
4.24 g/rev
0.11 g/hole
5.39 g/rev
0.13 g/hole
0.5 RPM
11.5 RPM
0.27 lb/hr
0.12 kg/hr
0.35 lb/hr
0.15 kg/hr
6.33 lbs/hr
2.87 kg/hr
8.00 lbs/hr
3.62 kg/hr
Default
CT21710
calibration #
4.00 g/rev
1.0 RPM
38 RPM
0.55 lb/hr
0.25 kg/hr
0.70 lb/hr
0.32 kg/hr
21.19 lbs/hr
9.61 kg/hr
27.08 lbs/hr
12.28 kg/hr
See Note 4
Consult factory - 40 pocket disc and 35.5 rpm motor for small
pellets and coarse powder only
051725
0.2 RPM
3 RPM
0.2 RPM
8.4 RPM
0.20 lb/hr
0.09 kg/hr
0.20 lb/hr
0.09 kg/hr
0.24 lb/hr
0.11 kg/hr
0.24 lb/hr
0.11 kg/hr
2.92 lbs/hr
1.32 kg/hr
8.18 lbs/hr
3.71 kg/hr
3.70 lbs/hr
1.68 kg/hr
10.37 lbs/hr
4.70 kg/hr
4-10
0-051725
DD3
5 mm thick
17 mm dia.
25 pockets
7.37 g/rev
0.30 g/hole
9.38 g/rev
0.38 g/hole
0.5 RPM
11.5 RPM
0.48 lb/hr
0.22 kg/hr
0.61 lb/hr
0.27 kg/hr
11.0 lbs/hr
4.99 kg/hr
14.0 lbs/hr
6.36 kg/hr
CT21711
Default
calibration #
7.30 g/rev
1.0 RPM
38 RPM
See Note 4
1.00 lb/hr
0.44 kg/hr
1.25 lbs/hr
0.57 kg/hr
37.04 lbs/hr
16.80 kg/hr
47.10 lbs/hr
21.36 kg/hr
051818
0.2 RPM
3 RPM
0.2 RPM
8.4 RPM
0.35 lb/hr
0.16 kg/hr
0.35 lb/hr
0.16 kg/hr
0.44 lb/hr
0.20 kg/hr
0.44 lb/hr
0.20 kg/hr
5.34 lbs/hr
2.42 kg/hr
14.96 lbs/hr
6.79 kg/hr
6.80 lbs/hr
3.08 kg/hr
19.03 lbs/hr
8.63 kg/hr
4-11
0-051818
DD3
5 mm thick
18 mm dia.
18 pockets
13.42 g/rev
0.75 g/hole
17.08 g/rev
0.95 g/hole
0.5 RPM
11.5 RPM
0.85 lb/hr
0.39 kg/hr
1.12 lbs/hr
0.51 kg/hr
19.60 lbs/hr
8.89 kg/hr
25.63 lbs/hr
11.62 kg/hr
CT23057
Default
calibration #
13.50 g/rev
1.0 RPM
38 RPM
See Note 4
1.76 lbs/hr
0.80 kg/hr
2.20 lbs/hr
1.00 kg/hr
67.44 lbs/hr
30.59 kg/hr
85.90 lbs/hr
38.95 kg/hr
Note 1: This guide is to be used for general disc selection for Digital Dosing unit applications. All rates shown are based on
continuous throughput of free-flowing materials. Consult factory for regrind, powder and all hard-to-flow materials.
Note 2: Minimum recovery time is one (1) second, and maximum rate is 9.5 disc revolutions in one screw recovery cycle (injection
mode). Use correct disc for molding applications to ensure proper dispensing of material during the recovery cycle.
Note 3: Feeder should not run continuously below 15% of maximum speed – use lower RPM motor or disc with smaller pockets.
Note 4: 35.5. and 38 rpm motors can only be used with soft pellets – may not have enough torque to cut hard pellets, i.e. PC, PET,
nylon, etc., especially when the shear gets dull.
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Disc
Nomenclature
Min/Max
Disc RPM
Amount of Material Dispensed
every Disc Revolution*
Minimum Throughput -
Continuous Running*
Maximum Throughput -
Continuous Running*
Disc
35 lbs./ft3
44 lbs./ft3
35 lbs./ft3
44 lbs./ft3
35 lbs./ft3
44 lbs./ft3
101820
0.2 RPM
3 RPM
0.75 lb/hr
0.34 kg/hr
1.00 lb/hr
0.43 kg/hr
11.11 lbs/hr
5.04 kg/hr
14.1 lbs/hr
6.4 kg/hr
DT30 101820
10 mm thick
18 mm dia.
20 holes
0.2 RPM
8.4 RPM
0.75 lb/hr
0.34 kg/hr
1.85 lbs/hr
0.84 kg/hr
1.00 lb/hr
0.43 kg/hr
2.31 lbs/hr
1.05 kg/hr
31.11 lbs/hr
14.11 kg/hr
42.23 lbs/hr
19.15 kg/hr
39.5 lbs/hr
17.9 kg/hr
52.7 lbs/hr
23.9 kg/hr
28.0 g/rev
1.4 g/hole
35.6 g/rev
1.7 g/hole
Default
calibration #
28.00 g/rev
0.5 RPM
11.5 RPM
CT23056
1.0 RPM
38 RPM
3.7 lbs/hr
1.68 kg/hr
4.70 lbs/hr
2.14 kg/hr
140.76 lbs/hr
63.85 kg/hr
179.0 lbs/hr
81.2 kg/hr
P102520
0.2 RPM
3 RPM
0.87 lb/hr
0.40 kg/hr
1.12 lbs/hr
0.50 kg/hr
13.10 lbs/hr
5.94 kg/hr
16.6 lbs/hr
7.5 kg/hr
DT30-102520
“Sure-shot”
10 mm thick
Oval Hole
18mm x 25mm
20 holes
0.2 RPM
8.4 RPM
0.87 lb/hr
0.40 kg/hr
1.12 lbs/hr
0.50 kg/hr
36.67 lbs/hr
16.63 kg/hr
46.6 lbs/hr
21.1 kg/hr
33.6 g/rev
1.3 g/hole
42.7 g/rev
1.7 g/hole
0.5 RPM
11.5 RPM
2.18 lbs/hr
0.99 kg/hr
2.77 lbs/hr
1.26 kg/hr
49.77 lbs/hr
22.57 kg/hr
63.3 lbs/hr
28.7 kg/hr
CT66707
1.0 RPM
38 RPM
4.36 lbs/hr
1.98 kg/hr
5.55 lbs/hr
2.52 kg/hr
165.81 lbs/hr
75.21 kg/hr
211.1 lbs/hr
95.7 kg/hr
Default
calibration #
33.00 g/rev
203012
0.2 RPM
3 RPM
2.51 lbs/hr
1.14 kg/hr
3.13 lbs/hr
1.42 kg/hr
37.73 lbs/hr
17.11 kg/hr
47.1 lbs/hr
21.3 kg/hr
DT30-203012
20 mm thick
30 mm dia
12 holes
0.2 RPM
8.4 RPM
2.51 lbs/hr
1.14 kg/hr
3.13 lbs/hr
1.42 kg/hr
105.66 lbs/hr
47.93 kg/hr
131.9 lbs/hr
59.8 kg/hr
95.0 g/rev
7.9 g/hole
118.7 g/rev
9.8 g/hole
Default
calibration #
95.00 g/rev
0.5 RPM
11.5 RPM
6.28 lbs/hr
2.85 kg/hr
7.80 lbs/hr
3.54 kg/hr
143.28 lbs/hr
65.00 kg/hr
178.0 lbs/hr
80.7 kg/hr
CT23060
1.0 RPM
38 RPM
12.50 lbs/hr
5.70 kg/hr
15.65 lbs/hr
7.10 kg/hr
477.99 lbs/hr
216.81 kg/hr
596.8 lbs/hr
270.7 kg/hr
204010F
0.2 RPM
3 RPM
4.00 lbs/hr
1.80 kg/hr
5.00 lbs/hr
2.25 kg/hr
60.00 lbs/hr
27.22 kg/hr
75.0 lbs/hr
34.0 kg/hr
DT30-
204010F
20 mm thick
40 mm dia
10 pockets
0.2 RPM
8.4 RPM
4.00 lbs/hr
1.80 kg/hr
5.00 lbs/hr
2.25 kg/hr
168.00 lbs/hr
76.20 kg/hr
210.0 lbs/hr
95.2 kg/hr
151.1 g/rev
15.1 g/hole
188.7 g/rev
18.8 g/hole
0.5 RPM
11.5 RPM
10.00 lbs/hr
4.53 kg/hr
12.43 lbs/hr
5.64 kg/hr
227.74 lbs/hr
103.28 kg/hr
283.5 lbs/hr
129.0 kg/hr
Default
CT18405
calibration #
150.00 g/rev
1.0 RPM
38 RPM
20.00 lbs/hr
9.00 kg/hr
25.00 lbs/hr
11.30 kg/hr
754.65 lbs/hr
342.30 kg/hr
948.3 lbs/hr
430.1 kg/hr
P250940
0.2 RPM
3 RPM
0.20 lb/hr
0.093 kg/hr
0.26 lb/hr
0.115 kg/hr
3.07 lbs/hr
1.40 kg/hr
3.87 lbs/hr
1.76 kg/hr
DP30-250940
2.5 mm thick
9 mm diameter
40 pockets
0.2 RPM
8.4 RPM
0.20 lb/hr
0.093 kg/hr
0.26 lb/hr
0.115 kg/hr
8.61 lbs/hr 3.91
kg/hr
10.83 lbs/hr
4.91 kg/hr
7.8 g/rev
0.2 g/hole
9.7 g/rev
0.24 g/hole
0.5 RPM
11.5 RPM
0.46 lb/hr
0.21 kg/hr
0.60 lb/hr
0.27 kg/hr
10.79 lbs/hr
4.90 kg/hr
13.57 lbs/hr
6.15 kg/hr
Default
calibration #
7.80 g/rev
CT100864
1.0 RPM
38 RPM
1.00 lb/hr
0.47 kg/hr
1.30 lbs/hr
0.58 kg/hr
39.28 lbs/hr
17.82 kg/hr
49.08 lbs/hr
22.26 kg/hr
P050940
0.2 RPM
3 RPM
0.41 lb/hr
0.187 kg/hr
0.51 lb/hr
0.23 kg/hr
6.19 lbs/hr
2.81 kg/hr
7.73 lbs/hr
3.51 kg/hr
DP30-050940
5 mm thick
9 mm diameter
40 pockets
0.2 RPM
8.4 RPM
0.41 lb/hr
0.187 kg/hr
0.51 lb/hr
0.23 kg/hr
17.33 lbs/hr
7.86 kg/hr
21.66 lbs/hr
9.82 kg/hr
15.6 g/rev
0.3 g/hole
19.5 g/rev
0.4 g/hole
Default
calibration
#15.00 g/rev
0.5 RPM
11.5 RPM
1.00 lb/hr
0.45 kg/hr
0.12 lb/hr
0.57 kg/hr
22.62 lbs/hr
10.62 kg/hr
28.65 lbs/hr
13.80 kg/hr
CT100863
1.0 RPM
38 RPM
2.00 lbs/hr
0.94 kg/hr
2.60 lbs/hr
1.17 kg/hr
78.57 lbs/hr
35.64 kg/hr
98.16 lbs/hr
44.52 kg/hr
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Appendix C Drawings
Single Station Digital Dosing Feeder
SIDE VIEW
TOP VIEW
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“Duo” Digital Dosing Feeder
SIDE VIEW
TOP VIEW
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Electrical Schematics of A250 Controller
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Appendix D Spare Parts List
Dosing Disc/Shear Order Numbers
Dosing disc
72 chambers
40 chambers
25 chambers
18 chambers
CT100562
CT21710
CT21711
CT2057
Dosing disc, wear-resistant
CT28214
40 chambers
25 chambers
18 chambers
CT27141
CT27142
Shear for DD style feeder
18, 25 and 40 pocket disc
72 pocket disc
CT21392
CT100875
Replacement Motor Assembly Part Numbers
Gear Motor Assemblies
Bodine
Bauer
N/A
3 RPM
892.02095.00
CT34300
6.4 RPM
11.5 RPM
35.5 RPM
8.4 RPM
11.5 RPM CT102241
38 RPM CT34299
NOTE: Bauer (blue) and Bodine (black & silver) motors are mechanically
interchangeable, with changes to controller parameters # 7 and # 8.
(See page 20 & 21)
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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. A customer replacement parts list
is included in this manual for your convenience. ACS welcomes inquiries on all your parts
needs and is dedicated to providing excellent customer service.
Service Department
[
]
[
Call toll-free 8am–5pm CST 800 423-3183 or call 262] 641-8610
[
]
Emergencies after 5pm CST, call 847 439-5655
We have a qualified service department ready to help. Service contracts are available for most
Sales Department
[
Call 262] 641-8610 Monday–Friday, 8am–5pm CST
Our products are sold by a worldwide network of independent sales representatives. Contact
our Sales Department for the name of the sales representative nearest you.
Contract Department
[
Call 262] 641-8610 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or non-
union installations
Sterling, Inc.
2900 S. 160th Street
New Berlin, WI 53151
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