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Manual Sterling BF3-600

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  • Sterling BF3-600 - page 1

    Digital Dosing Units 1 SDD Digital Dosing Units Part Number: 882.00276.00 Bulletin Number: BF3-600 Effective: 12/01/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed ...

  • Sterling BF3-600 - page 2

    Please note that our address and phone infor mation has changed. Please reference this page for updated contact information . These manuals are obsolet e and are provided only for their techni cal informat ion, data and capacities. Portions of th ese manuals detai ling procedur es or precauti ons in the operation, inspec tion, m ain tenance and rep ...

  • Sterling BF3-600 - page 3

    Digital Dosing Units 2 Table of Contents SECTION 1: INTRODUCTI ON …………….…………… ………….………...3 1.1 Controller . ..............................................................................................................4 1.2 Keys and Symbols............................................................................ ...

  • Sterling BF3-600 - page 4

    Digital Dosing Units 3 Section 1: Introduction This User’s Manual is intended for use with th e Digital Dosing Additive Feeder. The feeder precisely meters and controls the addition of mast er batches, chemical additives, and r egrinds to primary plastics. The Digital Dosing unit can meter both powde r and granular material of various sizes. It c ...

  • Sterling BF3-600 - page 5

    Digital Dosing Units 4 Figure 2. 2 Station Digital Dosing Unit Q U I C K S T A R T P A G E S H A V E B L U E B O R D E R ...

  • Sterling BF3-600 - page 6

    Digital Dosing Units 5 1.1 Contr oller The Digital Dosing additive feeder consists of a controller, dosi ng m otor, and feeder(s). The controller is used to • Enter, recall, and run recipes • To run, monitor, and stop the dosing process • To calibrate • To troubleshoot probl ems via error codes • To configure the unit to the desired proce ...

  • Sterling BF3-600 - page 7

    Digital Dosing Units 6 1.2 Keys and Symbols Recipe Storage/Recall: For saving, recalling or modifying recipes. Stop : Stops the continuous operation of the feeder. W ill reset the totalizer showing metered amount of additive to zero if depressed f or two seconds. Up-arrow : For increasing the set value in de cimal increments. Down- arro w: For decr ...

  • Sterling BF3-600 - page 8

    Digital Dosing Units 7 Symbols Lights when the run signal from the pro cess machine is rece ived by the Digital Dosing controller. During operation, lights when the disc is dosing material. During calibration and recipe input/viewing, lights when a ca libration weight is input or viewed. (EXTRUSION ONLY) Lights when a screw speed signal is received ...

  • Sterling BF3-600 - page 9

    Digital Dosing Units 8 Section 2: Quick Start-up Quick Start is intended to help you in startin g up your Digital Dosing feeder quickly and easily. Please refer to the manual to go into gre ater detail. Unpacking: 1. Unpack box, making sure all parts indi cated on packing list are included. 2. Check all parts and equipment for any damage sustained ...

  • Sterling BF3-600 - page 10

    Digital Dosing Units 9 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 gram s. 4. Press Input to display #3, “Screw recovery time”. Using arrow keys, set the screw recovery time (in seconds). For Ex trusion Constant operation, skip this ...

  • Sterling BF3-600 - page 11

    Digital Dosing Units 10 6. Repeat step #19 four more times, each time en tering the new weight from the scale into the controller using the arrow keys. Sometim es the values w on’t change, or sometimes they may only change by a few tenths of a gram. The contro ller keeps a running average of all calibration weights enter ed. 7. After all five sam ...

  • Sterling BF3-600 - page 12

    Digital Dosing Units 11 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 a ffected by machine vibration, therefore best performance is achieved by mounting the unit dire ctly to the fee ...

  • Sterling BF3-600 - page 13

    Digital Dosing Units 12 be exposed to extreme heat (maxim um temperature 45 ° C or 115 ° F) or excessive moisture. 4. Electrical connection to process machine: • Injection Molding : Connect the cycle/run slave ca ble (thin two-conductor cable) to a set of DRY (NO VOLTAGE) contacts that CLOSE for the duration of screw recovery. See Figure 5, ele ...

  • Sterling BF3-600 - page 14

    Digital Dosing Units 13 NOTE: Zero input corresponds to zero scre w speed and no additive dosing. Maximum input corresponds to maximum screw speed. NOTE: If a 0-10kHz frequency input is used, it must be a square wave with an amplitude of 12VDC. The shape of the signal is important, especially above 7,000Hz. J12-4 _ J12-3 + 0-10vdc or 0-20ma Extrude ...

  • Sterling BF3-600 - page 15

    Digital Dosing Units 14 • Recipe parameters are different for Injection Molding, Extrusion-Constant, and Extrusion-Proportional operation. See each ind ividual section for details. • The calibration method is the sa me for all processes. • Once the unit is online, the user may want to save recipes for later reca ll (10 maximum). • This sect ...

  • Sterling BF3-600 - page 16

    Digital Dosing Units 15 • Enter the additive perc entage 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 d ouble arrow key allows the user to ramp up or down by larger increments.) Step 2: • Press Input again. • The symbols “ g ,” or “ lb ...

  • Sterling BF3-600 - page 17

    Digital Dosing Units 16 this value during operation. The range of va lues that can be entered in this field is 00.50 to 99.99 seconds. Step 4: • Press Input a fourth time. • The symbols “ g ” or “ lb ”and flash. • After “4” quickly flashes on the screen, a number in the format xxxx.x will com e up on the display. • Enter the mat ...

  • Sterling BF3-600 - page 18

    Digital Dosing Units 17 • After “5” flashes on the display, a numb er in the format xxx.xx will come up on the display. • Enter the maintained running time of the blending unit in seconds using the arrow keys. This is how long the blende r will run after each dosing cycle and should be adjusted for the best possi ble blend. Too little time ...

  • Sterling BF3-600 - page 19

    Digital Dosing Units 18 1. Pressing again will first display th e number “18” and then will display the total throughput in kilograms (totalizer). Operation-Injection Molding 1. Ensure that the unit is properly installed (Section 3.1), a recipe is entered (section 3.3.1), and the feeder is calibrated (Sec tion 3.6), before attempting to begin o ...

  • Sterling BF3-600 - page 20

    Digital Dosing Units 19 light on the controller during screw recovery. The disc symbol will light when the Digital Dosing unit is dosing material. • The totalizer will in crease after each cycle by th e amount of material dosed. • To stop the dosing process, press . • While the unit is dosing , the current recipe can be viewed, but not modifi ...

  • Sterling BF3-600 - page 21

    Digital Dosing Units 20 • Press once. • The symbol will flas h. • After “1” flashes on the screen, a number in the format xxx.xx will come up on the display. • Enter the additive perc entage 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 d ...

  • Sterling BF3-600 - page 22

    Digital Dosing Units 21 • Press a third time. • The machine displays a flashing , “g” or “lb” and a number “4”flashes on the display (because this is Extrusion Constant, step 3 is skipped). • After the “4” flashes on the display, a number in the form at xxxx.x will come up. • Enter the calibration weight. If the calibration ...

  • Sterling BF3-600 - page 23

    Digital Dosing Units 22 Step 5: 6. Press again. 7. The number “18” will be display ed before the total throughpu t in kg is displayed. Operation –Extrusion Constant 1. Ensure that the unit is properly installe d (Section 3.1), a recipe is entered (Section 3.4.1), and the feeder is calibrated (Sec tion 3.6), before attempting to begin operatio ...

  • Sterling BF3-600 - page 24

    Digital Dosing Units 23 NOTE: See Appendix A, Troubleshootin g, for information on problems or errors encountered and their resolution . 3.5 Extrusion Pr oportional Recipe Input – Extrusion Proportional To enter a recipe for Extrusion Proportiona l, the following process data is required: • Percentage of additive • Expected throughput of the ...

  • Sterling BF3-600 - page 25

    Digital Dosing Units 24 Step 2: • Press again. • The machine displays a flashing “ g ” or “ lb ”, a flashing “ min ” and . • After “2” flashes quickly on the display, a number in the format xxx.xx will come up on the display. • Enter the expected extrud er throughput during producti on in grams per minute or pounds per minut ...

  • Sterling BF3-600 - page 26

    Digital Dosing Units 25 Step 4: 1. Press a fourth time. 2. The machine displays a flashing and “ g ”. 3. After “4” flashes quickly on the screen, a number in the form at xxx.xx will come up on the display. • Enter the calibration weight in grams or pounds. If the calibr ation weight is unknown, enter “00.00” and complete th e calibrat ...

  • Sterling BF3-600 - page 27

    Digital Dosing Units 26 2. Place the Digital Dosing unit into op eration by pressing the Run key ( ). The green LED will light when the unit is ready to dose, but will not feed until the extruder begins operation. 3. Start the extruder. The Di gital Dosing unit will begin dosing material as soon as the extruder starts. If the unit is inst alled pro ...

  • Sterling BF3-600 - page 28

    Digital Dosing Units 27 Determining the Calibration Weight Step 1: • To start the calibration proce ss, press the calibration key. Step 2: • Once the sample container is in position, press . • The disc will rotate 1/4 revolution an d dispense material in to the sample container. After the disc stops, the screen will remain blank. • This sam ...

  • Sterling BF3-600 - page 29

    Digital Dosing Units 28 • The disc will rotate one full revolution. After the disc has stopped rotating, a number in the format “xx.xx” will ap pear on the screen along with a flashing and “ g .” Step 4: • Enter the weight, in grams using the Arrow Keys • Empty and replace weighing container in calib ration box (or under material outl ...

  • Sterling BF3-600 - page 30

    Digital Dosing Units 29 • Pressing the stop button will stop pro portioning a nd not accept the calibration weight. • Pressing the calibration button will stop proportioning and accept the calibration weight. NOTE: It is normal for calibration weights to vary slightly from sa mple to sample. ...

  • Sterling BF3-600 - page 31

    Digital Dosing Units 30 Section 4: Advanced Operations/ Control Functions 4.1 Recipe S torage And Recall A maximum of ten (10) recipes can be stored and retrieved with the Digital Dosing controller in the Recipe Storage/Recall mode. Recipes are st o red using a two-digit identification number. Pressing at any time will exit the Recipe Storage/Recal ...

  • Sterling BF3-600 - page 32

    Digital Dosing Units 31 • Press and hold the button until the totalizer display returns to the screen. • The recipe is now stored under the selected ID number. Recipe Recall Step 1: • Press the stop button to st op any current applications. Step 2: • Press the Storage/Recall key ( ) once. • A two-digit recipe ID number will appear on sc r ...

  • Sterling BF3-600 - page 33

    Digital Dosing Units 32 • Press and hold until the totalizer ap pears on the screen. • The recipe is now active and can be run or edited. NOTE: The recalled recipe now becomes the active recipe. 4.2 Clearing The T otalizer • The totalizer displays the tota l amount of additiv e dosed since the last time the totalizer was cleared. • The tota ...

  • Sterling BF3-600 - page 34

    Digital Dosing Units 33 Alarms Several alarm options are available for the Digita l Dosing feeder. The standard unit comes with a flashing alarm symbol on the faceplate. Options includ e both audible horns and flashing lights. An optional no voltage alar m relay can be connected to the user’s central alarm system. Level Probes To adjust the level ...

  • Sterling BF3-600 - page 35

    Digital Dosing Units 34 Mixer An optional mixer is available that can be mount ed under the Digital Dosing unit. The m ixer is used to help distribute fine pow ders and granules. During the injection molding process, the mixer only runs during screw recovery (when th e Digital Dosing unit is dosing additives). During extrusion processes, the mixer ...

  • Sterling BF3-600 - page 36

    Digital Dosing Units 35 Figure Section 5: Maintenance 5.1 Maintenance Intervals Daily: Check warning signs on equipment for good legibility and completeness. Weekly: Check function of the on/off Switch. Every 3 months: Check scraper in dosing station DD/DT. Every 6 months: Check all electrical and mechanical connections for tight fit. Check adjustm ...

  • Sterling BF3-600 - page 37

    Digital Dosing Units 36 6. Remove the dosing unit from the dosing motor. 7. Remove the cover from the connectin g piece (D). 8. Loosen the two screws (C) on the unde rside of the dosing unit housing (E). 9. Remove the scraper (A). Installing the scraper 1. Place the new scraper in the dosing unit housing. 2. Ensure that the scraper is positioned c ...

  • Sterling BF3-600 - page 38

    Digital Dosing Units 37 5. Remove the dosing hopper from the dosing unit. 6. Dismantle the dosing unit and rem ove the scraper (D). 7. Loosen the two hexagon socket screws (B, M6 x 30) on the top side of the dosing disc (A). 8. Loosen the center hexagon socket screw (C, M6 x 12) and replace by an M6 x 60 screw. 9. Lift the dosing disc (A) from the ...

  • Sterling BF3-600 - page 39

    Digital Dosing Units 38 5.4 Changing the Dosing Disc in the Digital Dosing Dosing S tation Removing the Dosing Disc 1. Empty the dosing station. 2. Switch the control unit off by means of the on/off switch. 3. Dismantle the dosing unit a nd remove the scraper. 4. Loosen the two hexagon socket screws (M 6 x 30) on the top side of the dosing disc. 5. ...

  • Sterling BF3-600 - page 40

    Digital Dosing Units 39 Installing Different Types of Dosing Discs Dosing discs of the same type may be exchange d for each other without any problem s. If dosing discs with a different compartment num ber are in stalled, this has to be entered in the control system! 1. Enter the (preliminary) calibra tion value of the freshly inst alled dosing dis ...

  • Sterling BF3-600 - page 41

    Digital Dosing Units 40 9. Install the dosing container along with th e dosing hopper on the dosing housing (pay attention to the guide pins). 10. Mount the profile clamp. 11. Mount the screw at the profile clamp. 5.6 Cleaning the DT Dosing S tation 1. Empty the dosing station. 2. Switch the control unit off by means of the on/off switch. 3. Discon ...

  • Sterling BF3-600 - page 42

    Digital Dosing Units 41 17. Install the dosing container along with th e dosing hopper on the dosing housing (pay attention to the guide pins). 18. Mount the profile clamp. 19. Mount the screw at the pr ofile clamp and tighten. 5.7 Exchangeable S tations Dosing discs of the same type may be exchange d for each other without any problem s. If dosing ...

  • Sterling BF3-600 - page 43

    Digital Dosing Units 42 6. Never try to repair a defective fuse. 7. Open the screws (A) and remove the lid (B). 8. Remove the blind lid (C) and open the screws. 9. Move the lid (D) aside. 10. Remove the defective fuse from the fuse carrier. 11. Install the new fuse (while obs erving the value). 12. Mount the lid (D). 13. Fasten the screws a nd the ...

  • Sterling BF3-600 - page 44

    Digital Dosing Units 43 Appendix A: Troubleshooting During setup and use of the Digital Dosi ng Additive Feeder, personnel may experience difficulties. Some of the problems encountered may be reso lved using the following techniques. A.1 General T roubleshooting - Unit W ill Not Operate • Check all connections and process wiring. No te that the p ...

  • Sterling BF3-600 - page 45

    Digital Dosing Units 44 ERROR CODES Code Definition Possible Reason/Solution A001 Strap “safety switch” is missing. Manufacturer Service. A002 The nominal current of the dosing motor (=100%, see name plate) is being exceeded for more than 2 seconds by 30% or for a maximum of 0.5 seconds by 80%. Dosing motor defective or jammed. Check the dosing ...

  • Sterling BF3-600 - page 46

    Digital Dosing Units 45 A.3 Determining the Softwar e Setup Factor The Digital Dosing control unit is configured via a Software Set up Factor (binary code). To determine the Software Setup Factor answer th e following questions: If th e answer is “yes” enter the code number in the selec tion colum n. If the answer is “no” enter “0” in t ...

  • Sterling BF3-600 - page 47

    Digital Dosing Units 46 Disc RPM ( Additive - %) x (Total Extruder Throughput - lb / hr) 13.22 x (Disc Calibration Weight - g) = Recipe Limitations Extrusion Mot or Ass emb ly S pe ed ( RPM ) Max imu m Speed (RPM) 12 12.5 38 40.0 ...

  • Sterling BF3-600 - page 48

    Digital Dosing Units 47 Appendix B: Basic Parameter Settings Extrusion Mode: You need an extruder signal that is proportional to the extruder speed to operate in the Extrusion Proportional mode. You can use any of the following: • Frequency signal (must be 12VDC square wave) • 0-20mA current signal • 0-10VDC signal Determine the frequency out ...

  • Sterling BF3-600 - page 49

    Digital Dosing Units 48 If a current signal is available (0 - 20 m A) calculate the frequency output of the extruder for the lower / upper working area using the formula: Frequency [Hz] = Input current [mA] x 10000 [Hz] 20 [mA] Note the data: Min. input frequency = __________ Hz Max. input frequency = __________ Hz Calculate the span factor using t ...

  • Sterling BF3-600 - page 50

    Digital Dosing Units 49 Alarm output is switched in case of power failure . . . . . . . . . . . 512 ___ Extrusion mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024 ___ Printer available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16348 ____ Configuration value: . . . . ...

  • Sterling BF3-600 - page 51

    Digital Dosing Units 50 Totalizer displayed in lb (kg defa ult) . . . . . . . . . . . . . . . . . . . . . . . . . 16 ___ Shotweight up to 6.5 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 or Shotweight 6.5 to 65 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ___ (NOTE:The shotweight selections ...

  • Sterling BF3-600 - page 52

    Digital Dosing Units 51 Basic Parameter Settings ...

  • Sterling BF3-600 - page 53

    Digital Dosing Units 52 ...

  • Sterling BF3-600 - page 54

    Digital Dosing Units 53 ...

  • Sterling BF3-600 - page 55

    54 Appendix C: Disc Dosing Factor s And Equipment Drawings And Parts Numbers Disc Dosing Factor Table 1: Disc Guide Disc Disc Nomenclature Used in the Controller Minimum/ Maximum Disc Revolution Weight Per Disc Revolution (Bulk Density 35lb/cuft) Min. Throughput with 100% Continuous Running (Bulk Density 35lb/cuft) Max.Throughput with 100% Continuo ...

  • Sterling BF3-600 - page 56

    55 D30-051725 Default Calibration # 7.30 g/rev 051725 # of Hole s D iameter Disc Thi ckness 0.2 Rev./min 6.4 Rev. /min (6.4 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 7.37 g/Rev. 0.30 g/Hole 0.20 lb/hr 0.09 kg/hr 0.48 lb/hr 0.22 kg/hr 1.00 lb/hr 0.44 kg/hr 6.23 lb/hr 2.83 kg/h 11.0 lb/hr 4.99 kg/hr 34.60 lb/hr ...

  • Sterling BF3-600 - page 57

    56 DT30-102025 Sure-Shot disc No Picture Default Calibration # 33.00 g/rev P102025 # of Hole s D iameter Disc Thi ckness 0.2 Rev./min 6.4Rev./min (6.4 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 33.60 g/Rev. 1.3 g/Hole 0.87 lb/hr 0.40 kg/hr 2.18 lb/hr 0.99 kg/hr 4.36 lb/hr 1.98 kg/hr 27.94 lb/hr 12.67 kg/hr 49.7 ...

  • Sterling BF3-600 - page 58

    57 DP30 050940 Default Calibration # 15.00 g/rev P050940 # of Hole s Diam eter Disc Thi ckness 0.2 Rev./min 6.4Rev./min (6.4 RPM) 0.5 Rev./min 11.5 Rev./min (11.5 RPM) 1.0 Rev./min 35.5 Rev./min (35.5 RPM) 15.64 g/Rev. 0.39 g/Hole 0.41 lb/hr 0.187 kg/hr 1.00 lb/hr 0.45 kg/hr 2.00 lb/hr 0.94 kg/hr 13.20 lb/hr 6.00 kg/hr 22.62 lb/hr 10.62 kg/hr 73.40 ...

  • Sterling BF3-600 - page 59

    58 Specification Sheet DIGITAL DOSING UNIT TECHNICAL PARAMETERS Disc Dosing Factor Table 2 Maximum Number of Feed St ations One (1) for G ranule Processi ng Maximum Product Temperature 80 o C (or 176 o F) Weight (Approx imately) 20 kg (44 pounds) Connected Loads 0.11 kW Operating Vol tage 115/1/60 or 230/1/50-6 0 Special Voltage On Request Option L ...

  • Sterling BF3-600 - page 60

    59 Digital Dosing unit parameter setup 7-14 Biso n - Black motor Bauer - Blue motor Comments Parameter RPM 2 6 12 38 6.4 11.5 35.5 7 650 00 25200 14103 4387 117 39 6600 2135 These values refer to the pulses of the encoder 8 0.5 0.7 Nominal motor current 9 Ext Inj Ext Inj 104 0 16 104 0 16 (see separate calculatio n sheet for parameter #9) 10 0 1 Fa ...

  • Sterling BF3-600 - page 61

    ...

  • Sterling BF3-600 - page 62

    61 Station 1 Digital Dosing Unit SIDE VIEW TOP VIEW ...

  • Sterling BF3-600 - page 63

    62 Station 2 Digital Dosing Unit SIDE VIEW TOP VIEW ...

  • Sterling BF3-600 - page 64

    63 Dosing Unit Electrical Schematic Chart Drawing No. Description of Drawing Voltage CT102020 C150 CONTROLLER INJECTION 110 CT102021 C150 CONTROLLER EXT-S SIMPLE EXTRUSION 110 CT102022 C150 CONTROLLER EXT-V EXTRUSION 0-10 V INPUT 110 CT102023 C150 CONTROLLER EXT-C EX TRUSTION 0-20 mA INPUT 110 CT102024 C150 CONTROLLER INJECTION 220 CT102025 C150 CO ...

  • Sterling BF3-600 - page 65

    64 Appendix D: Spare Parts List Dosing Disc/Shear Order Numbers Dosing disc 72 chambers ID 100562 49 chambers ID 21710 25 chambers ID 21711 18 chambers ID 2057 Dosing disc, wear-resistant 40 chambers ID 28214 25 chambers ID 27141 18 chambers ID 27142 Shear for DD style unit 18, 25, 40 pocket disc ID 21392 72 pocket disc ID 100875 Shears Standard ID ...

  • Sterling BF3-600 - page 66

    65 - Notes- ...

  • Sterling BF3-600 - page 67

    66 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 630 ] 595- 1060, Fax [630] 475-7005 The ACS Customer Service Group will prov ide your com pany with genuine OEM qualit y parts manufactured to engineerin g design specificatio ns, which will maximize your equipment’s performance and efficiency. To as ...

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