Instruction/ maintenance manual of the product 882.01749.00 Sterling
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Digital Dosing Disc Additive Feeders Single, Duo and Trio With A250 Controller Part Number: 882.01749.00 Bulletin Num ber: BF3-600.5 Effective: 12/17/10.
882.01749.00 ii Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvem ent.
882.01749.00 iii Shipping Info Unpacking and Inspection You should inspect your granulator for possible ship ping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc.
882.01749.00 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual .
882.01749.00 v APPENDIX A BASIC PARAMETER SETTINGS ...................... 84 Injection Molding ............................................................................................................. ..... 84 Extrusion - Simple ..................
882.01749.00 6 of 93 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in a pplying efficient, proven techniques that enhance equipment productivity.
882.01749.00 7 of 93 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 com ponent s that are secured by wrench-type fasteners unless the motor is electrically locked out and the disc is motionless.
882.01749.00 8 of 93 1-4 Warnings and Precautions Our equipment is designed to provide safe and relia ble 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.
882.01749.00 9 of 93 Chapter 2: Functional Description 2-1 Introduction This manual is to be used with the Digital Dosing Disc additive feeder. T he feeder precisely meters and controls the addition of color concentrates, master batches, addi tives, regrind, and other materials to plastic processing systems.
882.01749.00 10 of 93 Figure 2. “Duo” Dual Stat ion Digital Dosing Feeder 2-1 A250 Controller The Digital Dosing additive feeder c onsists of a controller(s ), dosing m otor(s), and dosing m odule(s). The controller is used to: Configure the feeder to the desired process.
882.01749.00 11 of 93 2-2 Quick Start-Up Guide (See Chapter four for complete description) This “Quick Start” section is intended to help you start your Digital Dosing feeder quickly and easily. Please refer to the enclosed O & I manual for additional information.
882.01749.00 12 of 93 6. EXTRUSION – “Simple” : Connect the input cable (2-conductor ca ble-gray) to a dry contact (zero voltage) signal that indicates the extruder screw is turning. ( The connection in the controll er should be on terminal bloc k #10 and PLC input X5.
882.01749.00 13 of 93 Encoder pulses per disk revolution. See table . Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 Motor and alarm utilty selection Drive tuning .
882.01749.00 14 of 93 GR or OZ. Select the measure commonly used at your facility. Injection Press (GR/KG/OZ/LB) Select the measure commonly used at your facility. Additive sensor. Select the no sensor, alarm only, or alarm & stop. Virgin material sensor.
882.01749.00 15 of 93 Recipe Setup - Injection Molding: Turn power switch to “ON” position. Injection molding. In order to calculate the correct motor speed re quired to feed the desired amount of additive, the following data must be entered: 1) Additive % 2) Shot Size 3) Screw Recovery Time.
882.01749.00 16 of 93 Screw Recovery Time. The screw recovery time is the estimated screw recovery time, and is used as the initial value for validating the recipe. Actual screw recovery times as measured by the presence of the screw recovery signal, are used to fine-tune the feed rate during operation.
882.01749.00 17 of 93 “DT” Pellet & Regrind Discs “DP” Powder Discs Additive Sample weighing. W eighing samples of additive provides for more precise control of feed r ate. Up to 5 samples can be weighed. All weights entered are averaged to arrive at a value to be used during operation.
882.01749.00 18 of 93 Maximum Motor speed . Enter motor RPM. Encoder pulses per disk revolution. See table. Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.
882.01749.00 19 of 93 Drive tuning . Perform drive tuning. See section # for details. Speed Alarm setup . Select alarm option – Alarm & stop, alarm only, or no alarm. G R o r O Z S elect the measure commonly used at your facility. Extrusion Press (GR/KG/ OZ/LB) Select the measure commonly used at your facility.
882.01749.00 20 of 93 Virgin material sensor. Select the no sensor, alarm only, or alarm & stop. Recipe Setup for Simple Extrusion: 1. Turn power switch to “ON” position.
882.01749.00 21 of 93 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 t h e screen.
882.01749.00 22 of 93 “DT” Pellet & Regrind Discs “DP” Powder Discs Feeder Configuration – Extrusion follower: Touch the ACS logo on the main menu screen to access the configuration me nu. See section # for details. Feeder Type Selection .
882.01749.00 23 of 93 Enter/Read Minimum press signal. See section # for details. Enter/Read Maximum press signal. See section # for details. Maximum Motor speed Enter motor speed. Encoder pulses per disk revolution. See table. Manufacturer Motor Color RPM Encoder Pulses Bodine Black & silver 3 8400 Bodine Black & silver 8.
882.01749.00 24 of 93 Motor and alarm utilty selection Drive tuning Perform drive tuning. See section # f or details. S p e e d A l a r m s e t u p . Select alarm option – Alarm & stop, alarm only, or no alarm. G R o r O Z S elect the measure commonly used at your facility.
882.01749.00 25 of 93 Additive sensor. Select the no sensor, alarm only, or alarm & stop. Virgin material sensor. Select the no sensor, alarm only, or alarm & stop.
882.01749.00 26 of 93 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 t h e screen.
882.01749.00 27 of 93 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 30-0306 72 1.
882.01749.00 28 of 93 Press the “Menu” button to skip the weighing pro cedure 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.
882.01749.00 29 of 93 Screen 4. The disc will make one complete revolution, dispen sing 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.
882.01749.00 30 of 93 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 l ess than 5 samples have been taken, otherwise Screen 8 will be displayed.
882.01749.00 31 of 93 Chapter 3: Inst allation and Operation 3-1 Installation Direction of Material Flow Hopper Piece Processing Machine Figure 4. Digi tal Dosing Feeder Assembly 1.
882.01749.00 32 of 93 2. The following applications requi re a larger feed stand ( op tional 3” or 4”) to prevent material bridging: o Machines with a total th roughput 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.
882.01749.00 33 of 93 Extrusion - Constant : Wire the “cycle/run” cable (two- conductor gray cable) to a set of dry (NO VOLTAGE) contacts that CLOSE wh en the screw rotates. (See Figure 5.) The connection inside the controller shou ld be on terminal block #10 and PLC input X5.
882.01749.00 34 of 93 3-2 Initial Operation The control system is factory-progr ammed. However, specific values need to be verified prior to operation (basic parameter settings). The input values will be saved and still b e available if the feeder is switched off, or a power failure occurs.
882.01749.00 35 of 93 3-3 Recipes Recipe Menu The Recipe menu allows selection, editing, and deleti on 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 1 st recipe entry/editing screen.
882.01749.00 36 of 93 Enter / Edit Recipes. Injection molding. In order to calculate the correct motor speed re quired 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.
882.01749.00 37 of 93 Screw Recovery Time. The screw recovery time is the estimated screw recovery time, and is used as the initial value for validating the recipe. Actual screw recovery times as measured by the presence of the screw recovery signal, are used to fine-tune the feed rate during operation.
882.01749.00 38 of 93 Simple Extrusion Recipe. In order to calculate the correct motor speed re quired 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.
882.01749.00 39 of 93 Calibration weight. Calibration weight is determined from chart 5.1, an d is dependant on the disc inst alled in the feeder. This weight is the amount of standard density m aterial dispensed by the feeder during one revolution of the disc.
882.01749.00 40 of 93 The % additive specifies the proportion of additive to virgin material as a percentage of throughput . For example, if the throughput is 200 grams per minut e and 8.5 grams of additive are required, the additive percentage would be 4.
882.01749.00 41 of 93 Calibration weight is determined from chart 5.1, an d is dependant on the disc inst alled in the feeder. This weight is the amount of standard density m aterial 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.
882.01749.00 42 of 93 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. Discar d sample and replace container in calibration box.
882.01749.00 43 of 93 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.
882.01749.00 44 of 93 Screen 8. The tray should be removed from the calibrati on 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.
882.01749.00 45 of 93 Common Elements Buttons Press the Start button to begin feeding operation using the current recipe. Press the Stop button to end feeding operation.
882.01749.00 46 of 93 Speed Status Indicator If the speed alarm only option is selected in th e configuration section, the following indicators are enabled. Displays when the feeder speed exceeds the calculated sp eed by gre ater than that specified on the speed alarm setup screen.
882.01749.00 47 of 93 Totalizer Screen Displays total additive dosed since: A. Recipe change. Modifying the current recipe will not reset the total. Or B. Totalizer reset. The total is displayed in KG if recipe additive is measured in grams or kilograms.
882.01749.00 48 of 93 Displays the current motor speed when r unning, 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.
882.01749.00 49 of 93 Pressing and holding the Jog button will run the motor at the indicated speed for as long as the button is held. The length of time the m otor will run when the Run Motor button is pressed. Adjustable from 0 to 999 seconds. The default is 0 seconds.
882.01749.00 50 of 93 A) The Main Menu, using the Menu button. B) The System Setup Menu, using the Done button. C) The next Configuration screen, using the Next button. D) The previous Configuration screen, using the Prev button. System Setup Navigation Buttons.
882.01749.00 51 of 93 Table 4.1 Injection Press Screen # Title/Function Prev Scre en Next Screen 60 Press Type N/A Max Motor Speed 61 Max Motor Speed Press Type Encoder Pulses 62 Encoder Pulses Max Motor Speed Tune & Speed alarm 76 Tune & Speed alarm Encoder Pulses Default Add.
882.01749.00 52 of 93 61 Max Motor Speed Press Type Encoder Pulses 62 Encoder Pulses Max Motor Speed Tune & Speed alarm 76 Tune & Speed alarm Encoder Pulses Default Add. Measure 63 Default Add. Measure Tune & Speed alarm Default Shot Measure 65 Default Thruput Meas.
882.01749.00 53 of 93 Feeder Type. Feeder type is selected by pressing the button in th e upper-right corner. The button text changes with each press of the button in the following order: (Default Mod.
882.01749.00 54 of 93 Maximum Motor Speed. The maximum motor RPM is the maximum rated sp eed for the motor being used with the A250 control. The default nominal value is 11.5 RPM. This va lue should be changed to reflect the actual m o tor RPM based on motor type and tuning results (See Drive Tuning following this section).
882.01749.00 55 of 93 Bodine Black & silver 3 8400 Bodine Black & silver 8.4 8400 Bodine Black & silver 11.5 5700 Bodine Black & silver 38 1800 Motor and alarm utilty selection The Speed A larm settings screen can be activated by pressing the “Speed Alarm” button.
882.01749.00 56 of 93 Drive Tuning. The drive tuning screen is provided as an aid to tuni ng 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 c ontroller.
882.01749.00 57 of 93 Activate alarm screen & alarm outputs, and stop the feeder. See Status Screen s section for speed alarm screen details. Default Additive Measure .
882.01749.00 58 of 93 Default Shot Size / Throughput Measure. Injection Pre ss. Extrusion Press This screen sets the default measure for overall wei ght in recipes. While the measure can be changed in any recipe, this screen allows selection of the mo st commonly used unit of measure.
882.01749.00 59 of 93 Additive / Virgin Material Sensor . These screens select whether an additiv e (or virgin) material sensor is present and if so, what action to take when the sensor detects no material. Press the butt on in the upper right corner to sequence through the following options: No sensor is present.
882.01749.00 60 of 93 Press Signal Type. (Ext rusion Follower only) This screen selects the type of analog signal pr ovided by the press to communicate the press speed. Press the button in the upper right co rner to select from the following: 0 to 10 volts DC.
882.01749.00 61 of 93 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.
882.01749.00 62 of 93 Table 4.2 Password requirements. No Passwords Operator Only Setup Only Operator a nd . Set Active Active Setup Active Recipe Functions X O X O System Start/Stop X O X O Manual Jog/Run X O X O System Setup X O S S X - None O - Operator S - Setup Digital I/O Monitor.
882.01749.00 63 of 93 Analog / Encoder Monitor. This screen monitors the analog input & output, as well as the raw encoder value input . Additionally, the encoder can be connected to an alternate PLC input to help troubleshoot encoder problems.
882.01749.00 64 of 93 LED Y ellow (Station) on: Station Filled off: Station Emptied LED Green (Le vel Probe) on: P ower Supply A vailab le off: P ower Supply Not A vailab le T rim-pot with Plastic Screw M3 Cable Blind Lid Protective Scre w npn: Nor mally Closed pnp: Nor mally Open 10 npn: Nor mally Open pnp: Nor mally Closed Le vel Probe Figure 7.
882.01749.00 65 of 93 Communication Protocol Interfaces The Digital Dosing feeder can be controlled remo tely through ODBUS RTU protocol. Contact the Sales Department at 810.720.7300 for more inform ation. OPTIONAL Additive Hoppers Various styles of additive hoppers and options are also av ailable for the Digital Dosing feeder.
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882.01749.00 67 of 93 Virgin Material Supply Hoppers Various virgin material supply hopper options are available if your existing hopper will not work properly with the Digital Dosing feeder. Cont act the Sales Department at 810.720.7300 for more information.
882.01749.00 68 of 93 Chapter 4: Maintenance 4-1 Preventative Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the “On/Off” Switch. Check shear plate and mounti ng hardware in “DD” dosing station.
882.01749.00 69 of 93 “DD” Dosing Module - Pellets.
882.01749.00 70 of 93 Figure 4-2 Removing the Shear Plate (“DD dosing Module) Removing the shear 1. Turn “Off” off the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle la tches on the dosing motor. 4. Remove the dosing unit from the dosing motor.
882.01749.00 71 of 93 4-3 Removing the “DD” Disc a nd Cleaning the Dosing Module Dismantling the Dosing Module 1. Switch the contro l unit “Off” with the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches on the dosing motor.
882.01749.00 72 of 93 Installing the Dosing Module 1. Remove the screw (M6 x 30 or 60) from the center hole. 2. Place the dosing disc in the dosing unit housing . 3. Screw the dosing disc in place with two (2) M6 x 30 socket s crews, ensuring they are tight.
882.01749.00 73 of 93 “DT” Dosing Module - Pellets and Some Regrind.
882.01749.00 74 of 93 4-4 Removing/Replacing the Wipe r 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.
882.01749.00 75 of 93 4-5 Removing the “DT” Disc and cleaning the dosing station 1. Switch the control unit “Off ” with the “On/Off” switch. 2. Disconnect the power supply. 3. Open the toggle latches. 2. Remove the dosing hopper (D) from the motor.
882.01749.00 76 of 93 “DP” Powder Dosing Module.
882.01749.00 77 of 93 4-6 Removing/Replacing the “DT” Di sc & 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 latche s on the dosing motor.
882.01749.00 78 of 93 4-7 Removing the “DP” Disc a nd Cleaning the Dosing Station 1. Turn the control unit “Off”. 2. Disconnect the power supply. 3. Open the toggle latches. 4. Remove the dosing hopper (D). 5. Empty the dosing station. 6. Remove the profile clamp (C).
882.01749.00 79 of 93 4-8 Exchangeable Dosing Modules Dosing discs of the same type, i.e. “DD” may be exchanged for each other. (The 72 p ocket also requires a different shear plate.) If dosing discs with a different compartment num ber are installed, the new calibration number needs to be entered into the controlle r! 2.
882.01749.00 80 of 93 4-9 Spare Parts DD Dosing Units ITEM PART NO QTY U/M DESCRIPTION 1 CT18431 1 EA CALIBRATION BOX CDD CB/SB FIN 2 CT13007 1 EA DISC HSG DD30 MACH & HARDCOAT 3 CT13008 1 EA DRIV.
882.01749.00 81 of 93 DT Dosing Units ITEM PART NO QTY U/M DESCRIPTION 1 CT66122 1 EA DISC HOUSING DT30 10MM 2 CT66113 2 EA HOOK FOR DESTACO CLAMP 3 CT99113 1 EA BEARING 6010 2RSR 4 CT23056 1 EA DISC DT30, 20 POCKET 5 CT04294 1 EA COUPLING DRIVE CBQ/SB 6 CT92228 1 EA V-CLAMP DT30 DISC/INTERMEDIATE 7 CT99144 1 EA RETAINING RING 80X2.
882.01749.00 82 of 93 DP Dosing Units ITEM PART NO QTY U /M DESCRIPTION 1 882.00569.00 1 EA D ISK, HSG, TIGHT TOL, DP30 2 CT66113 2 EA HOOK FOR DESTACO CLAMP 3 CT99113 2 EA BEARING 6010 2RSR 4 CT99114 2 EA RETAINING RIN G 80 X 2. 5 5 CT66298 1 EA DISC METERING DP30-5 NYLON 6 CT66109 1 EA H UB K1DP DISK KCT 7 882.
882.01749.00 83 of 93 DD/DT/DP Additional Spare Parts ITEM PART NO QTY U /M DESCRIPTION 1 892.01046.00 1 EA COVER WITH KNOB, SS FOR ACRYLIC HOPPER 2 832.00040.00 1 EA ACRYLIC H OPPER, 4.4 LITER, ACR YLIC ONLY 3 832.00041.00 1 EA ACRYLIC H OPPER, 8.8 LITER, ACR YLIC ONLY 4 892.
882.01749.00 84 of 93 Appendix A Basic Parameter Settings A-2 Recipe Formulas The following formulas can be used to determin e if a recipe is appropriate or possible. Injection Molding For injection molding a pplications, compute th e dosing disc speed and total number of disc revolutions using the following fo rmulas.
882.01749.00 85 of 93 Appendix B Disc Sizing Guides Disc Disc Nomenclature Min/Max Disc RPM Amount of Mate r ial Dispensed every Disc Revolution* Minimum Throughput - Continuous Running* Maximum Throughput - Continuous Running* 35 lbs./ft 3 44 lbs./ft 3 35 lbs.
882.01749.00 86 of 93 Disc Disc Nomenclature Min/Max Disc RPM Amount of Mate r ial Dispensed every Disc Revolution* Minimum Throughput - Continuous Running* Maximum Throughput - Continuous Running* 35 lbs./ft 3 44 lbs./ft3 35 lbs./ft 3 44 lbs./ft 3 35 lbs.
882.01749.00 87 of 93 Appendix C Drawings Single Station Di gital Dosing Feeder SIDE VIEW TOP VIEW.
882.01749.00 88 of 93 “Duo” Digital Dosing Feeder SIDE VIEW TOP VIEW.
882.01749.00 89 of 93 Electrical Schematics of A250 Controller.
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882.01749.00 91 of 93 Appendix D S p are Part s List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers CT100562 40 chambers CT21710 25 chambers CT21711 18 chambers CT2057 Dosing disc, wear-resis.
882.01749.00 92 of 93 Appendix E T e chnical Assist ance 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.
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An important point after buying a device Sterling 882.01749.00 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling 882.01749.00 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling 882.01749.00 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling 882.01749.00 you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling 882.01749.00 will certainly help you make a decision on the purchase.
If you already are a holder of Sterling 882.01749.00, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling 882.01749.00.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling 882.01749.00. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling 882.01749.00 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
