Sterling 00276.00 User Manual
SDD Series Digital Dosing
Additive Feeders
Part Number: 882.00276.00
Bulletin Number: BF3-600.2
Effective: 11/01/06
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change
without notice.
DCN No. ____________
© Copyright 2006
All rights reserved.
Table of Contents
SECTION 1: INTRODUCTION …………….……………………….……….........................3
1.1 C150 Controller... .....................................................................................5
1.2 Keys and Symbols ...................................................................................6
SECTION 2: QUICK START-UP……………………………………...…….........................8
BASIC INPUT PARAMETERS – INJECTION MOLDING...……...……...12
BASIC INPUT PARAMETERS – EXTRUSION...................……...……...16
SECTION 3: INITIAL INSTALLATION AND OPERATION ............................…………20
3.1 Initial Installation .....................................................................................20
3.2 Initial Operation ......................................................................................23
3.3 Injection Molding..................................................................................... 24
3.4 Extrusion - Constant ............................................................................... 29
3.5 Extrusion - Proportional (Extruder tracking, or follower) .........................34
3.6 Calibration ..............................................................................................38
SECTION 4: ADVANCED OPERATIONS/CONTROL FUNCTIONS.…....................…41
4.1 Recipe Storage/Recall............................................................................ 41
4.2 Clearing the Totalizer .............................................................................43
4.3 Acknowledging Alarms ........................................................................... 43
4.4 Optional Equipment ................................................................................ 44
SECTION 5: MAINTENANCE……………...……………………………..…......................46
5.1 Maintenance Intervals ............................................................................46
5.2 Removing the Shear Plate (DD feeder only)........................................... 46
5.3 Cleaning the “DD” Dosing Station........................................................... 47
5.4 Changing the Dosing Disc in the “DT” Dosing Station ............................ 49
5.5 Removing/Replacing the Wiper in the “DT” Dosing Station .................... 50
5.6 Cleaning the “DT” Dosing Station ........................................................... 49
5.7 Exchangeable Stations........................................................................... 52
5.8 Changing Fuses .....................................................................................53
APPENDIX A: TROUBLESHOOTING………………...................…………...………..…54
A.1 General Troubleshooting........................................................................54
A.2 Malfunctions — Error Codes .................................................................. 54
A.3 Determining the Software Setup Factor ................................................. 56
A.4 Recipe Formulas ....................................................................................56
APPENDIX B: BASIC PARAMETER SETTINGS………………...................………..…58
APPENDIX C: DISC DOSING FACTORS, DRAWINGS AND PARTS NUMBERS......63
APPENDIX D: SPARE PARTS LIST…...………………………………....................……76
APPENDIX E: Technical Assistance...…..…………………………….......................…79
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Section 1: Introduction
This User’s Manual is intended for use with the Digital Dosing Disc Additive Feeder. The
feeder precisely meters and controls the addition of master batches, chemical additives, and
regrinds to primary plastics. The Digital Dosing unit can meter both powder and granular
material of various sizes. It can be used on extrusion, blow molding and injection molding
machines. Depending on the application and throughput, two models are available: Single
Station Digital Dosing Unit or Dual Station Digital Dosing Unit. See Figures 1 and 2. This
manual covers the operation of both units.
I
C
K
S
T
A
R
T
P
A
G
E
S
Figure 1. Single Station Digital Dosing Unit
(Shown with optional virgin supply hopper and controller mounting plate)
H
A
V
E
B
L
U
E
B
O
R
D
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R
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Figure 2. Dual Station Digital Dosing Unit
(Shown with optional virgin supply hopper and controller mounting plate)
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1.1 Controller
The Digital Dosing additive feeder consists of a controller(s), dosing motor(s), and feeder(s).
The controller is used to:
• Configure the unit to the desired process.
• Calibrate the feeder
• Run, monitor, and stop the dosing process
• Enter, recall, and run recipes
• Troubleshoot problems via error codes
A keypad and LED display (see Figure 3) are used to enter, or change, data.
• The control system is switched on (position “1") with the On/Off switch. (A)
• The control system is operated through the keypad. (B)
• The individual operating modes are indicated by symbols. (C)
• Messages appear on a 5-digit LED display. (D)
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Figure 3. Keypad and LED Display
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1.2 Keys and Symbols
Recipe Storage/Recall: For saving, recalling or modifying recipes.
Stop: Stops the continuous operation of the feeder. Will reset the totalizer
showing metered amount of additive to zero if depressed for two seconds.
Up-arrow: For increasing the set value in decimal increments.
Down-arrow: For decreasing the set value in decimal increments.
Arrow Key: For fast increasing/decreasing of the set value in larger increments.
Must be pressed simultaneously with the up- or down-arrow.
Run: Starts the continuous operation (LED is lit up) or calibration mode (LED
flashes)
Calibration Key: Switches from operation to calibration mode. LED flashes
when calibration process has started.
Input: Selects the next screen for the input of program parameters.
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Symbols
Lights when the run signal from the process machine is received by the Digital
Dosing controller.
During operation, lights when the disc is dosing material. During calibration and
recipe input/viewing, lights when a calibration weight is input or viewed.
(EXTRUSION ONLY) Lights when a screw speed signal is received from the
extruder during proportional extrusion control (tracking, or following)
Lights when an alarm occurs.
Percent additive
Kilograms
Grams
Pounds
Minutes
Seconds
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Section 2: Quick Start-up
Quick Start is intended to help you in starting up your Digital Dosing feeder quickly
and easily. Please refer to the manual to go into greater detail.
Unpacking:
1. Unpack box, making sure all parts indicated on packing list are included.
2. Check all parts and equipment for any damage sustained during shipment.
3. If any damage is noted, contact manufacturer for replacement or service.
4. Make sure the following are present before proceeding:
; Power source 110 or 220 volt, single phase, 50 or 60 hertz (verify voltage on
Serial Number tag
; Proper mounting flange adapter 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 complete unit, including dosing hopper full of material, on the feed throat
(may need an adapter for feed throat).
2. Identify the motor drive connector (“Amp” connector-black) and connect to motor.
3. Identify the communication cable (DB-9 plug-silver) and connect to DB-9 connector
under motor drive assembly.
4. Identify power cord and plug into appropriate outlet.
5. INJECTION MOLDING: Identify the cycle/run cable (2-conductor cable-gray) for
connection to a dry (ZERO VOLTAGE) contact that closes during the screw recovery
cycle of the molding machine.
6. EXTRUSION: Identify the input cable (2-conductor cable-gray) for connection to 0-10
VDC or 0-20 mA signal that indicates speed (rpm) of the extruder.
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Recipe Setup for Injection Molding:
1. Turn power switch to ON position.
2. Press Input to display # 1, “Additive %”. Using arrow keys, set additive ratio.
3. Press Input
to display #2, “Shot size of current mold”. Using arrow keys, set the
total shot size (parts and runners) of the current mold capacity in grams/pounds.
4. Press Input to display # 3, “Screw recovery time”. Using arrow keys, set the
screw recovery time (in seconds).
5. Press Input to display # 4, “Calibration weight for additive”. Enter the appropriate
value from the range table below and proceed to calibration mode below for calibration
of additive material.
DD Discs
Disc Calibration Number
Range
DD 30-030672 1.75
DD 30-051040 5.00
DD 30-051725 8.00
DD 30-051818 15.00
DT Discs
Disc Calibration Number
Range
DT 30-101820 32.00
DT 30-102025 38.00
DT 30-203012 100.00
DT 30-204010 175.00
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DP Discs
Disc Calibration Number
Range
DP 30-050940 17.00
DP 30-250940 8.00
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Recipe Setup for Extrusion:
1. Turn power switch to ON position.
2. Press Input to display # 1, “Additive %”. Using arrow keys, set additive ratio.
3. Press
Input to display # 2, “Throughput of extruder”. Using arrow keys, set the
total extruder throughput in g/min or lb/min.
4. Press Input to display # 3, “Extruder screw speed”. Using arrow keys, set the
extruder screw speed RPM expected during production.
NOTE: For Extrusion - Constant operation, the above step will be skipped.
5. Press Input to display # 4, “Calibration weight for additive”. Enter the appropriate value
from the range table on page 9 and proceed to calibration mode below for calibration
of additive material.
Calibration:
1. Press “Calibration” button to start this procedure. Display will show - - - -
2. Place the plastic calibration cup on the scale and tare so that the weight of the cup
(approx. 24 grams) is not calculated in the calibration procedure.
3. Remove cover of the calibration box, secured by two 5 mm Allen screws, under the
dosing disc assembly and insert plastic cup provided in top of dosing hopper.
4. Press “Run” and the dosing disc turns 1/4 turn. This fills all pockets of dosing
disc. Dump the dosed material back into the dosing hopper without weighing and
replace plastic cup in calibration box.
5. Press
“Run” and the dosing disc turns 1 complete revolution. Remove the
calibration cup with the material and place on the gram scale. Enter the weight on the
scale into the controller using the arrow keys. Empty and replace calibration
cup.
6. Repeat step # 5 four more times, each time entering the new weight from the scale
into the controller using the arrow keys. Sometimes the values won’t change, or
sometimes they may only change by a few tenths of a gram. The controller keeps a
running average of all calibration weights entered.
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7. After all five samples have been completed; press “run” once more and this will save
the calibration weight of the material to the recipe. The calibration light will go out and
the screen will now show the total amount of additive dosed. The Digital Dosing feeder
is now ready to begin operation.
8. Please refer to “Operation Manual” for all supplementary information regarding
general operation, cleaning/maintenance, and troubleshooting.
9. Make sure that there is a virgin material supply setup to begin processing. If you do
not have a loader or hopper for the virgin material, or if any of the above procedures
did not work properly, please contact ACS Technical Support @ (800) 423-3183
(8 AM - 5 PM) CST.
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Basic Input Parameters for Digital Dosing Feeder with
Injection Software (P1._ _ - Older units) or (P2._ _ - newer units)
Hold Stop and Input buttons until “7” flashes
- Enter the input number for the specific motor from the table below.
- This value sets the impulses of the encoder.
Manufacturer Motor Color RPM Input Number
Bauer
Bauer
Bauer
Bison
Bison
Bison
Bison
Blue
Blue
Blue
Black
Black
Black
Black
6.4 11739
11.5 6600
35.5 2135
2 65000
6 25200
12 14103
38 4387
Press Input button
- When “8” flashes, enter 0.7 for Blue Bauer motor.
- Or, enter 0.5 for the black Bison or Colorblend S motor.
- This value sets the nominal current for the motor.
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Press Input button
-When “9” flashes, enter the configuration value.
- Please see the list: “Determining Configuration Value” for more information.
Press Input button
- When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
- If any another motor is intended for use, enter 0.
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Press Input button
- When “11” flashes, enter 50
- This value is the minimum input frequency.
Press Input button
− When “12” flashes, enter 5.56
− This value is the span factor.
Press Input button
− When “13” flashes, enter the communication address.
− If Euromap17 is not intended to for use, enter 0.
− This value is the communication address. Only enter a value here if Euromap17
report is in use.
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Press Input button
− When “14” flashes, enter 220
− This value is for the material contents of the mixing hopper.
− Only in case of mounting on a micro mixing-hopper.
Press Stop to exit parameters, “18” will flash, then it automatically returns to the totalizer
screen
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Basic Input Parameters for Colorblend C-150 with
Extrusion Software (E1._ _ - Older units) or (E2._ _ - newer units)
Hold Stop and Input buttons until “7” flashes
- Enter the input number for the specific motor from the table below.
- This value sets the impulses of the encoder.
Manufacturer Motor Color RPM Input Number
Bauer
Bauer
Bauer
Bison
Bison
Bison
Bison
Blue
Blue
Blue
Black
Black
Black
Black
6.4 11739
11.5 6600
35.5 2135
2 65000
6 25200
12 14103
38 4387
Press Input button
- When “8” flashes, enter 0.7 for blue Bauer motor.
- Or, enter 0.5 for the black Bison or Colorblend S motor.
- This value sets the nominal current for the motor.
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Press Input button
- When “9” flashes, enter the configuration value.
- Please see the list: “Determining Configuration Value” for more information.
Press Input button
- When “10” flashes, enter 1 if a blue Bauer motor is intended for use.
- If any another motor is intended for use, enter 0.
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Press Input button
- When “11” flashes, enter 50
- This value is the minimum input frequency.
Press Input button
− When “12” flashes, enter 10
− This value is the span factor.
Press Input button
− When “13” flashes, enter the communication address.
− If Euromap17 is not intended to for use, enter 0.
− This value is the communication address. Only enter a value here if Euromap17
report is in use.
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Press Input button
- When “14” flashes, enter 220
-
This value is for the material content of the mixing hopper.
- Only in case of mounting on a micro mixing-hopper.
Press Stop to exit parameters, “18” will flash, then it automatically returns to the totalizer
screen.
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Section 3: Initial Installation and Operation
3.1 Initial Installation
Direction of Material Flow
Hopper Piece
Processing
Machine
Figure 4. Digital Dosing Unit Assembly
1. The Digital Dosing additive feeder is not affected by machine vibration, therefore best
performance is achieved by mounting the unit directly to the feed throat of the molding
machine or extruder (see Figure 4). The inlet into the process machine must be
greater than 2” diameter; otherwise, an adapter might be necessary. If an adapter is
necessary, it must be designed so that there are no edges where material can be
trapped. The adapter must be smooth to promote even material flow. Consult factory
for any special requirements.
2. Optimum mounting of the Digital Dosing feeder is shown in Figure 4, with the additive
being dosed on the first screw flights.
3. The controller can be mounted on either side of the blender base to optimize operator
interface. An optional remote mounting kit for the controller is available from the
manufacturer to relocate the controller closer to the operator. The control unit must not
be exposed to extreme heat (maximum temperature 45°C or 115°F) or excessive
moisture.
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4. Electrical connection to process machine:
• Injection Molding: Connect the cycle/run slave cable (thin two-conductor
cable) to a set of DRY (NO VOLTAGE) contacts that CLOSE for the duration
of screw recovery. See Figure 5, electrical diagram.
J12-3
J12-2
Relay contact
Injection molding Digital Dosing controller
Machine
(Electrical diagram of connections)
Figure 5. Electrical Diagram
• Extrusion - Constant: Wire the cycle/run slave cable (thin two- conductor cable) to
a set of DRY (NO VOLTAGE) contacts that CLOSE when the screw rotates. See
Figure 5 for electrical diagram.
• Extrusion - Proportional: Wire the cycle/run slave cable to the extruder signal
output that is proportional to the extruder speed. The signal output can be one of
the following: 0-10 VDC or 0-20 mA. Please refer to the labels on the cycle/run
slave cable for the correct input to avoid damaging the controller. Digital Dosing
Additive Feeder should be configured from the factory for each specific input.
See Figure 6 for analog inputs.
NOTE: Voltage from Extruder needs to be isolated. Consult factory for other signal
requirements. External signal converter may be required.
NOTE: Zero input corresponds to zero screw speed and no additive dosing.
Maximum input corresponds to maximum screw speed.
NOTE: If a 0-10 kHz frequency input is used, it must be a square wave width and
an amplitude of 12 VDC. The shape of the signal is important, especially
above 7,000 Hz.
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J12-4 _
J12-3 +
0-10 VDC or 0-20 mA
Extruder output Digital Dosing controller
(diagram of analog inputs)
Figure 6. Analog Inputs
5. Make sure the unit is turned OFF before plugging it in. The switch toward the rear of
the controller unit should be in the OFF, or “O” position. Standard operation voltage is
110 or 220 VAC, 50/60 Hz, single-phase power. Special voltages are available, refer
to voltage label on the feeder to determine the correct operating voltage.
Extruder Follower Interface Signal Converter
Isolating power sources and sensor signals is the most effective method for eliminating
undesirable ground loop currents and induced electrical noise.
To determine the correct signal convert to use:
o Define whether a current (mA) or voltage (dc) signal from the extruder is
available to utilize.
o The range should be either be 0-20 mA or 0-10 VDC, respectively.
o The controller has no specific requirement other than the signal being isolated
and proportional to the speed of the extruder.
Signal Converter with AC Power Supply
Vendor: Phoenix Contact
Order Designation: MCR-FL-C-UI-UI-DCI-24/230
Supply Voltage: 20V to 253V AC/DC
Input 4-20 mA, 0-10 VDC (Quantity: 1)
Output 0-20 mA, 0-10 VDC (Quantity: 1)
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Signal Converter with DC Power Supply
This module requires a separate 24 VDC power supply.
Vendor: Phoenix Contact
Order Designation: MCR-FL-C-UI-2UI-DCI-NC
Supply Voltage: 20 to 30V DC
Input 4-20 mA, 0-10V (Quantity: 1)
Output 0-20 mA, 0-10V (Quantity: 2)
24 VDC Mini Power Supply
A Phoenix Contact power supply for the Phoenix Contact signal conditioner listed above.
Vendor: Phoenix Contact
Order Designation: MINI-PS-100-240AC/24DC/1
Please note that the data given here has been taken from Phoenix Contact's online catalog.
For comprehensive information and data, please refer to the user documentation at
http://www.download.phoenixcontact.com.
3.2 Initial Operation
The control system is factory-programmed. Nevertheless, specific values need to be
predefined or checked prior to operation (basic parameter settings). The input values will be
saved and will still be available if the unit 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. Please refer to Appendix B.
Prior to putting your new Digital Dosing Additive Feeder on-line:
• You must enter a recipe and calibrate the feeder.
• Recipe parameters are different for Injection Molding, Extrusion - Constant,
and Extrusion - Proportional operation. See each individual section for
• The calibration method is the same for all processes.
• Once the unit is online, recipes can be saved for later recall (10 maximum).
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• This section will show how to calibrate the unit, bring the unit on line, enter a
recipe, and store and recall recipes.
3.3 Injection Molding
During each molding cycle the Digital Dosing unit doses the correct amount of additive evenly
throughout the screw recovery cycle. The Digital Dosing unit determines the correct amount
of additive from the recipe and automatically adjusts the duration and speed of dosing by
measuring the molding machine screw recovery time each cycle.
Recipe Input - Injection Molding
To enter a recipe for injection molding, the following process data is required:
• Percentage of additive
• Total shot weight in grams (includes parts and runner system)
• Screw recovery time of the machine in seconds
• Calibration weight in grams
• Step 1:
• Press Input once.
• The LED symbol flashes.
• “1” will quickly flash on the display, before a number in the format xxx.xx
comes up on the display.
• Enter the additive percentage by using the Arrow Keys
.
(The range of values that can be entered is 0.01% to 50.00%. The arrow
keys are used to change all process variables. The double arrow key allows
the user to ramp up or down by larger increments.)
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