MANUAL Colorfeed CF 390. CF390_eng_1108_N docx

MANUAL Colorfeed CF 390 CF390_eng_1108_N06 550 115.docx SIA ATEC Engineering 15/25 Jurkalnes Street Office 211 Riga LV-1046 Latvia Tel: +371 6780 48...
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MANUAL Colorfeed CF 390

CF390_eng_1108_N06 550 115.docx

SIA ATEC Engineering 15/25 Jurkalnes Street Office 211 Riga LV-1046 Latvia Tel: +371 6780 4870 Fax: +371 6780 4872 www.atecgroup.net

INDEX INDEX 2 Safety regulations ................................................................................................................ 1.1 Safety instructions for putting into service:........................................................... 1.2 Safety Instructions for use: .................................................................................. 1.3 Safety instructions for maintenance: .................................................................... 1.4 Manufacturers liability (guarantee)....................................................................... 1.5 Figures and symbols ........................................................................................... 2 Colorfeed 390 ...................................................................................................................... 3 Installation............................................................................................................................ 3.1 Neckpiece ........................................................................................................... 3.2 Dosing unit .......................................................................................................... 3.3 Material hopper ................................................................................................... 3.4 Dosing screw....................................................................................................... 3.5 Exchangeable sleeve .......................................................................................... 4 Delivery versions.................................................................................................................. 5 Accessories.......................................................................................................................... 5.1 Adaptor for neckpiece.......................................................................................... 6 Semi automatic calibration system ....................................................................................... 7 The menu structure of the Colorfeed controller .................................................................... 8 At first start-up...................................................................................................................... 8.1 Main menu .......................................................................................................... 8.2 Main settings ..................................................................................................... 8.3 Language .......................................................................................................... 8.4 Working mode (Run mode)................................................................................ 9 Discontinuous run (for example injection moulding machine) ............................................. 9.1 Dosing settings................................................................................................. . 9.2 Dosing menu ..................................................................................................... 10 Continuous run (for example extrusion).............................................................................. 10.1 Dosing settings................................................................................................. . 10.2 Dosing menu ..................................................................................................... 11 Calibration.......................................................................................................................... 11.1 To make a calibration ........................................................................................ 11.2 Calibration point 1 ............................................................................................. 11.3 Calibration 2 ...................................................................................................... 12 Calibration info ......................................................................................................... .......... 13 Emptying and cleaning ....................................................................................................... 14 Changing of screw ........................................................................................................ ..... 15 Changing the sleeve ...................................................................................................... .... 16 Changing the hopper....................................................................................................... ... 17 Maintenance ..................................................................................................................... . 18 Electrical connection .................................................................................................... ...... 19 Guide capacities ......................................................................................................... ....... 21 Technical specification ....................................................................................................... 22 Spare parts list ......................................................................................................... .......... 1

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3 4 4 5 5 5 6 7 7 7 7 7 7 8 8 8 9 9 9 9 10 10 10 11 11 12 13 13 13 14 14 15 15 16 17 17 18 18 18 19 20 21 22

Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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1

Safety regulations

(Following the provisions of Directive 89/392/EEC Appendix 1) Date of manufacture: 2011 ICEVA AB PLASTGATAN 15 S-261 73 HÄLJARP SWEDEN Tel. +46 418 44 90 50 Fax. +46 418 43 54 99

Model: Dosing unit Colorfeed CF 390 Expected use of the machine. Colorfeed is a modular volumetric dosing system for granular and free flowing material and powder, constructed for use in the plastic industry. Besides the smaller dosing units CF 390 - which is described in this manual - we also have the bigger dosing units CF 500 and CF 600. The modules come in different designs, which you are able to combine. In this manual the dosing units are described in their standard format, but have been completed with necessary additions in specific cases. If you need further information, please contact your Colorfeed distributor, or us direct. Colorfeed CF 390 meets the demands of the directives of EU, consequently CE-marked and approved for selling and using within the EU. Read this manual carefully and following general rules: -

Never use the dosing unit for things other than it’s meant for

-

Modifications or additions may not be made without our approval

-

Always use original spare parts

-

Send back to your distributor for service and repairing

-

Earth connections should be made according to local regulations

-

Always keep your fingers and tools away from the dosing unit openings, when voltage is on. The dosing unit is very often synchronised with the process-machine and may therefore start automatically

-

Switch off the voltage - remove the fuse - before accessing the dosing unit

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1.1

Safety instructions for putting into service:

Before installing this product, please read carefully all information in the directions for use. There are much information that is important for using and maintaining the dosing unit correctly. Save the directions for use. The manufacturer disclaims all responsibility if the following instructions are not followed. 1. Remove all packing carefully and see to that it will be taken care of in a lenient way for the environment. 2. Never use a damaged dosing unit. Contact the supplier if you are uncertain. 3. The dosing unit may only be used for the purpose mentioned earlier. 4. The dosing unit is connected in accordance to the instructions for the electrical installation. Line voltage must correspond to the specifications on the connection diagram and the rating plate. 5. The electrical safety is dependent of correct installation and connection to a correctly grounded socket. Make sure that the wire will not get squeezed. 6. Installation according to national and local directions. 7. Inside the controller is current carrying (230 VAC). 8. The unit is made for indoor use only, and may not be exposed to moisture or liquids. Allowed working temperature; 0-40°C. 9. An authorized electrician must install the unit. Improper installation could result in personal injuries from electrical shock and equipment damage. 10. Personnel with knowledge of the product must change the value on the smart relay. Improper use could result in personal injuries from electrical shock and damage equipment.

1.2 Safety Instructions for use: 1. The lids of the dosing unit shall always be mounted. 2. The material hopper shall always be mounted. 3. The lid of the control box shall always be locked when in use. 4. Always keep your fingers and tools away from the dosing unit openings, when voltage is on. The dosing unit is very often synchronized with the processing machine and may therefore start automatically. 5. Before the control box or the lids of the dosing unit is opened, make sure that the main power source is disconnected. Improper use could result in personal injuries from electrical shock and equipment damage.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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1.3

Safety instructions for maintenance:

1. Maintenance and repairs may only be executed by personnel with knowledge of the product. 2. When maintaining and repairing the dosing unit, the dosing unit may not be connected to the electricity and compressed air supply system. Pull out the plug and disconnect the compressed air supply. Always contact ICEVA AB by the slightest sign of defect.

1.4

Manufacturers liability (guarantee)

This unit has a 1-year guarantee. The guarantee expires if:

The unit is installed incorrectly, or by unauthorized personnel. The unit is used in a way it is not intended.

1.5

Figures and symbols This symbol means dangerous voltage (115-400Vac). This symbol means, crush hazard.

This symbol means, read the manual.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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Colorfeed 390

Colorfeed dosing units CF 390 in their standard format consist of: 1. 2. 3. 4. 5. 6.

Neckpiece. Exchangeable sleeve. Dosing house with emptying cover. Motor with coupling and motor cover. Hopper with lid and sight glass Dosing screw with coupling

Module number and serial number are written on the dosing house and on the controller.

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Installation

3.1

Neckpiece

Drill holes in the bottom flange of the neckpiece to fit the material inlet of the process machine and in the upper flange to fit the material hopper for the main material. Mount the neckpiece. Then attach the hopper for main material to the upper flange of the neckpiece. Use a mounting position that exposes the dosing unit to least heat and vibration.

3.2

Dosing unit

Insert the dosing unit into the neckpiece and match the groove in the outlet with the end of the knob and tighten the knob. Use the mounting which exposes the dosing house and the motor to the least heat and vibration. Warning! Always keep your fingers and tools away from the dosing unit openings, when voltage is on. The dosing unit is very often synchronised with the processing machine and may therefore start automatically.

3.3

Material hopper

The material hopper is normally mounted in the dosing house on delivery. There are three standard sizes 3 liter N51 900 301 6 liter N51 900 302 10 liter N51 900 304

3.4

Dosing screw

The dosing screw is normally mounted in the dosing house on delivery. A complete dosing screw consists of: Dosing screw with bearing, coupling and rubber connector. Available standard sizes, see spare part list page17.

3.5

Exchangeable sleeve

The sleeve is normally mounted in the dosing house on delivery. Available standard sizes, see spare part list page17.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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Delivery versions

The dosing unit has an exchangeable dosing screw and sleeve. The outlet end of the dosing screw is free floating as standard but a dosing screw that is supported at both ends is also available. The sleeve, screw, motor and controller are ordered separately.

5

Accessories

5.1

Adaptor for neckpiece

If more than one dosing unit CF 390 needs to be mounted on a neckpiece use the adaptor N51 900 332 to fit on neckpiece N51 906 502 and the adapter

Warning! Always keep your fingers and tools away from the dosing unit openings, when voltage is on. The dosing unit is very often synchronised with the processing machine and may therefore start automatically.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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Semi automatic calibration system

This volumetric dosing unit is equipped with a semi automatic calibration system to make it easy to handle. This means that if you put in the values for the dosing settings and making a manual calibration (take out samples, weighing it and type the value to the controller) the controller calculates the speed setting by this values. You do not need to time the calibration or make any calculations by yourself.

7

The menu structure of the Colorfeed controller

The controller is designed with 10 numerical keys, C, comma and two function keys (F1 and F2). The numerical keys are used to put in values or chose a sub menu. C erases the last input value.

The function keys are interactive and have different functions depending on which menu you are in. The lower row on the display shows what function the key has in this specific menu. It can for example be start dosing, stop or continue. From the main menu you can chose different sub menus. 1 3 4 5

8

Dosing Dosing settings Calibration Calibration data

At first start-up

At first start up you need to do some setups, it’s the language and working mode. The working mode is the related to which kind of machine the dosing unit is connected to. There are two main mode Injection moulding machine (IMM) and extruder. In the IMM mode the dosing unit is running discontinuous in the extrusion it´s running continuously. At delivery the unit is set to IMM and dynamic time if you want to choose some other working mode you need to change the working mode to make the unit run properly.

8.1

Main menu

Start screen by start up. Soft- and hardware version. After a few seconds the screen is changed to the main menu. HV 0,9 SW 0,9

Main menu In the main menu you can chose a number of different sub menus depending. You press a key to get to the desired sub menu, for example 1 to get to the dosing menu.

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1 2 3 4 5

Dosing Dosing settings Calibration Calibration data

Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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8.2

Password 4 digits

Main settings

In the controller there are menus for main settings that control how the unit works, what language etc. To reach these data you must log-in with a password. Press F1 and F2 simultaneously and you will go to the log-in menu. Put in the password (3333) and press OK.

XXXX XXXX

Esc

Under the menu setup 1 there are some sub menus possible to make alterations in, language and working mode.

Setup 1 1 Language 2 Zero point 3 Pulses per rev 4 Password 5 Working mode Esc Next

In the other pages/menus nothing should be changed as that would mean risk for the dosing unit not to work in the right way. Press desired key to get to the desired menu.

8.3

Language

To change language chose 1 language followed by the number for the language you want the menus in. Set Language 1 Swedish 2 English 3 German

Esc

8.4 Working mode (Run mode) The controller can be set in four different working modes, two for discontinuous run and two for continuous run. In all modes you need a closing potential free contact to start the dosing unit. The amount of material is set by the parameters set in the controller and the calibration. The four modes are: 1. Injection fixed time: for IMM, the loading time is set by a fixed time. 2. Injection dynamic: for IMM, the loading time is set to the previous loading time. 3. Extruder follow: for extruder, the amount of material from the dosing unit is proportional to the external tacho signal (0-10 Vdc) from the extruder. 4. Extruder fixed:

Run mode 1 Injection fixed time 2 Injection dynamic 3 Extruder follow 4 Extruder fixed Esc

For more information about the settings for an IMM go to chapter 9 and for an extruder go to chapter 10.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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9

Discontinuous run moulding machine)

(for

example

injection

When the Colorfeed unit is used on an injection molding machine the dosing unit is started and stopped synchronized with the loading (filling) time. You can choose between fixed and dynamic time. At fixed time the dosing motor starts when the potential free contact is closed and stops when the preset time has run out or the contact is opened. Note to get the right amount the set time must be shorter or the same as the loading time. The dosing unit will always stop when the contact is opened. If the set time is longer than the actual time there will be too less dosed material. At dynamic time (The standard working mode) the previous loading time is used to calculate the speed for the dosing screw this to get the right amount on each shot. The dosing unit starts when the contact is closed and stops when the contact opens. If the time is changing the setpoint will be recalculated so the amount of material will be constant. Note if the loading (filling) time is very unstable in every loading cycle chose fixed time instead.

9.1

Dosing settings

To set the dosing unit on the right dosing speed (setpoint) the following data must be put in. This is the first thing to do to get the best results for the dosing. To change any values press on the number on the keyboard. 1. Additive: The amount of additive you want to add in the product. In the example it will be 2,5%*232g= 5,8 g in every shot 2. Loading time: How long the loading (filling) time is. 3. Shot weight: The value for the product weight in grams. 4. Change: The unit is shifting between auto and manual.

Dosing settings 1 2 3 4

Additive Loading time Shot weight Change

2,5 % 12,5 s 232,0 g Auto

Esc

If a value is put in for additive, loading time or shot weight, the dosing unit wills automatic return to auto. If you want the controller to automatic calculate the speed on the screw you need to set the value to automatic and if you have changed material made a new calibration.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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9.2 Dosing menu Choose this menu when the dosing unit is in operation.

Dosing 1.Setpoint 2.Time

To return to the main menu press

570

Stop.

In the dosing menu the four different dosing values can be changed directly. If you for example press 3 a new value for the % of Additive can be set. Put in the new value and press F2 save to save the value or press F1 to exit without saving. To be able to quickly return to an earlier run without needing to calibrate the dosing unit, a manual setpoint and time can be put in. Additive and weight will then disappear from the menu. At the same time Auto will be changed to Manual in the dosing settings.

20,0

3. Add(%)

4.Weight

4,5

100,0 Stop

Setpoint min 20

162

Esc

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max 999 Save

Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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10

Continuous run (for example extrusion)

The two different working modes at continuous run are fixed setpoint and follow-on regulation. At fixed setpoint the speed of the dosing unit will follow the setpoint. At follow-on regulation the speed of the dosing unit follows setpoint and the reference signal (010 VDC) from the process machine. This relation is linear. When the reference signal is 10 V DC (signal 100 %) the dosing screw is rotating at the preset setpoint. At 5 V DC (signal 50 %) half the speed of the preset setpoint and so on. NOTE! On follow-on regulation the screw can rotate despite the signal is zero. Use the potential free contact to stop the unit. NOTE! The unit starts when the potential free contact is closed, see electrical drawing.

10.1 Dosing settings To set the dosing unit on the right dosing speed (setpoint) the following data must be put in. This is the first thing to do to get the best results for the dosing. To change any values press on the number on the keyboard. 1. Additive: The amount of additive you want to add in the product. In the example it will be 2,5%*60 kg/h = 1,5 kg/h 2. Capacity: The Capacity of the extruder in kg/h. 3. Change: The unit is shifting between auto and manual.

Dosing settings 1 Additive 2 Capacity 3 Change

2,5 % 60,0 kg/h Auto

Esc

If a value is changed for additive or capacity, the dosing unit wills automatic return to auto. If you want the controller to automatic calculate the speed on the screw you need to set the value to automatic and if you have changed material made a new calibration.

10.2 Dosing menu Choose this menu when the dosing unit is in operation. To return to the main menu press Stop. If the working mode is set to follow the follow-on signal (0-100%) is shown in this menu. As soon as you are in the dosing menu the process can be started. To stop and return to the main menu press Stop.

Dosing 1.Setpoint Folow %

570

20

3. Add(%)

4.Capacity

4,5

100,0 Stop

In the dosing menu there are three different dosing values that can be changed directly. If you for example press 3 a new value for the Additive can be set. Put in the new value and press F2 save to save the value or press F1 to exit without saving. To be able to quickly return to an earlier run without needing to calibrate the dosing unit, a manual setpoint and time can be put in. Additive and weight will then disappear from the menu. At the same time Auto will be changed to Manual in the dosing settings.

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Setpoint min 20

162

Esc

max 999 Save

Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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11

Calibration

This volumetric dosing unit is equipped with a semi automatic calibration system to make it easy to handle. This means that if you put in the values for the dosing settings and making a manual calibration the controller calculates the speed setting by these values. You do not need to time the calibration or make any calculations by yourself. The mentioned capacities in data sheets and manual shall only be seen as guidelines. When in production all relevant values must be used. As standard the dosing unit is set for two different calibrations, one at setpoint 800 and the other based on input values in the dosing settings menu.

11.1 To make a calibration

Calibration

Fill the Colorfeed hopper with additive and press 4 Calibration in the main menu and the press on F2 start. Loosen the knob on the neckpiece and pull pack the dosing unit. Open the calibration gate and place a cup under it, see picture

Earlier calibration will be erased. Do you want to continue?

Esc

Start

Calibration 1 Fill the dosing screw 2 Start calibration Cancel

To get an accurate calibration it is required that the dosing screw is filled with granules before the calibration is started. Press: 1 Fill the dosing screw  start (when you get out some material)  stop.

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11.2 Calibration point 1

Calibration

To start a calibration press F2 in the calibration menu. The controller proposes a setpoint, use this value for the best result. If you want another speed (setpoint) for the calibration press C and set the wanted value. Place an empty cup under the calibration gate and press F1 Start to start the dosing unit. By pressing F2 Stop the controller is automatically moved to the weight menu to add the weight. Weigh the dosed quantity, add the value and press F2 to save.

1 Fill the dosing screw 2 Start calibration Cancel

Weight

43,2 Esc

Save

11.3 Calibration 2 Depending on the input values in the dosing settings the system will calculate a setpoint which is close to the final setpoint, use this value for the best result. If you want change the setpoint press C and add the wanted value. Place an empty cup under the calibration gate and press F1 Start to start the dosing unit. By pressing F2 Stop the controller is automatically moved to the weight menu to add the weight. Weigh the dosed quantity, add the value and press F2 to save.

Calculated Setpoint C change setpoint Setpoint

380

.

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Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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12 Calibration info In this menu you can control calibration info in tables and diagram.

Calibration data 1 Table 2 Flow 3 Linearity Escape

Setpoint 1 Time 1 Weight 1 Setpoint 2

800 50,0 100,0 380

Time 2 Weight 2

23,5

SetP

X100

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13

Emptying and cleaning

Warning! Always turn off the main switch before you start service! You empty the hopper and dosing house through the emptying gate by pulling the emptying cover backwards on the dosing house. The hopper can now be cleaned. If cleaning completely, unscrew the dosing unit from the neckpiece and hold it with the outlet pointing downwards. Now start the dosing unit and run it until no more material is coming out. If compressed air is available, blow through the outlet to make the cleaning easier. If further cleaning is necessary, remove the dosing screw (see further under "CHANGING OF SCREW"). Warning! Always keep your fingers and tools away from the dosing unit openings, when voltage is on. The dosing unit is very often synchronised with the processing machine and may therefore start automatically. Warning! To avoid personal injuries use vacuum air instead of compressed air to clean the dosing unit. If you use compressed air always wear eye protection and observe all safety regulations pertaining to the use of compressed air.

14

Changing of screw

Warning! Always turn off the main switch before you start service! Empty the hopper and dosing house by opening the emptying cover. Unfasten the toggle latches on each side of the dosing unit. Pull the motor unit back and turn it to the left hand side. Pull out the screw for replacement or cleaning. Put back the screw and turn back the motor unit, fit in the rubber connector in the coupling, fasten the toggle latches and close the emptying cover.

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15

Changing the sleeve

Warning! Always turn off the main switch before you start service! Empty the hopper and dosing house by opening the emptying cover. Unscrew the dosing unit from the neckpiece. Loosen the bolt on the top of the outlet and the sleeve can be removed. A new sleeve can now be mounted and the screw tightened.

16

Changing the hopper Warning! Always turn off the main switch before you start service!

Empty the hopper and dosing house by opening the emptying cover. Unscrew the two screws on each side of the hopper. Pull the hopper backwards.

17

Maintenance

No special service is necessary, only normal control of function and calibration, and cleaning.

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Electrical connection

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Guide capacities

These capacity tests are done with HDPE, Ø 3 mm, density 0,956 kg/dm3 under continuous operation and should only be used as a guide in the choice of Colorfeed-type and screw combination.

Always try to make your choice to achieve a setpoint of 500 in order to get maximum flexibility and accuracy. Do not use setpoint lower than 33.

SETPOINT

50 rpm Power W

Screw

Screw/Sleeve Ø mm

500

999

Capacity kg/h

48

12

Free floating

5/12.

0,03

0,22

0,45

48

12

Free floating

8/16.

0,14

1,3

2,6

48

12

Free floating

12/20.

0,35

3,5

7,0

48

12

Supported

5/12.

0,02

0,22

0,45

48

12

Supported

8/16.

0,15

1,3

2,6

48

12

Supported

12/20.

0,40

3,5

7,0

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Technical specification

INPUT POWER:

(W)

MOTOR VOLTAGE:

12

(V DC) 0 - 12

CURRENT: CONTROL VOLTAGE FOR SPEED:

24

0 - 12

0-12

(A)

1

1

2

(V DC)

0-10

0-10

0-10

PWM

PWM

PWM

TYPE OF CONTROL: INPUT VOLTAGE:

12

(V AC)

230 ±15% , 50 Hz

CLASS OF INSULATION:

IP 54

IP 54

IP 54

SURROUNDING TEMPERATURE: (°C)

0-45

0-45

0-45

NOISE:

(dBA)

GEAR RATIO:

Lower than 70 100:1.

50:1.

15:1.

MAX. MOTOR SPEED:

(r/min)

24

48

133

SCREW SET DIMENSION

(mm)

5/8/12.

5/8/12.

5/8/12.

(l)

3/6/10.

3/6/10.

3/6/10.

(kg)

7

7

9

VOLUME MATERIAL HOPPER: WEIGHT:

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22 Spare parts list N51 701 3XX N51 604 3XX N51 608 533 N51 708 530 N51 608 318 N51 608 326 N51 608 319

Screw complete Dosing screw (XX= O.D. Ø5, Ø8 or Ø12) O-ring for seal washer Seal washer Coupling Connector clip Rubber connector

N51 603 3XX

Plastic sleeve (XX=I.D. Ø12, Ø14, Ø16, Ø18 or Ø20)

N51 701 2XX N51 604 2XX N51 608 533 N51 708 530 N51 608 318 N51 608 326 N51 608 319

Screw complete with support Dosing screw (XX= O.D. Ø5, Ø8 or Ø12) O-ring for seal washer Seal washer Coupling Connector clip Rubber connector

N51 603 2XX

Plastic sleeve with support (XX=I.D. Ø8, Ø10, Ø12, Ø14, Ø16, Ø18 or Ø20)

N51 705 305 N51 605 305 N51 608 317 N51 608 540

Motor with gear compl. 48 rpm Motor with gear 50:1 (12W) Coupling Motor cable

N51 705 405 N51 605 405 N51 608 317 N51 608 540

Motor with gear compl. 133 rpm Motor with gear 15:1 (24W) Coupling Motor cable

N51 705 306 N51 605 306 N51 608 317 N51 608 540

Motor with gear compl. 24 rpm Motor with gear100:1 (12W) Coupling Motor cable

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Tel +371 6780 4870 Fax +371 6780 4872

[email protected] www.atecgroup.net

Colorfeed 390 Art. no: N06 550 115 Version: 1101-English

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