dosing control

8/17/2019 Dosing Control

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WESTOMAT AUTOMATIC DOSING UNIT for ALUMINIUM

MELTin DIE-CASTING

00-B.doc Version: 03.00 A

OPERATING MANUALWESTOMAT® CONTROL

®

DPC


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WESTOMAT ProDos DPC

OPERATING MANUAL

00. 2 - 2 00-B.doc Version: 03.00 A DOSING CONTROL

STRIKOWESTOFEN GmbH

Lorenz-Schott-Strasse 5

D-55 252 MAINZ- KAS TEL Germany

Telepho ne: + 49 (0) 6134 207 6

Fax: + 49 (0) 6134 207 877

E-mail: [email protected]

Fritz-Kotz-Strasse 2-4

D-516 74 WI EHL- BOMIG Germany

Telepho ne: + 49 (0) 2261 7091 0

Fax: + 49 (0) 2261 7091 107

E-mail: [email protected]

http: //www.strikowestofen.com

VERMERK Diese Dokumentation ist urheberrechtlich geschützt und darf nur zu internemGebrauch in Ihrem Werk eingesetzt werden.Jede Vervielfältigung sowie jede Nutzung außerhalb Ihres Werkes ist untersagt.Sämtliche nicht ausdrücklich eingeräumten Rechte bleiben vorbehalten.


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WESTOMAT ProDos DPC

OPERATING MANUAL

DOSING CONTROL 0000-B.doc Version: 03.00 B 1 - 2

CONTENTS 00.00

NOTE This OPERATING MANUAL (Version 03.00 A) is valid for the following

ProDos ® DPC software versions: DPC – V1.01-05 and higher.

00. • COVER PAGE Version 03. 00 A

00.00 • CONTENTS Version 03. 00 B

01. HARDWARE Version 03.00 A

01.00 • ProDos ® DPC - WESTOMAT ® CONTROLSYSTEM

Version 03 .0 0 A

01.00.1 • SWITCHING ProDos ® DPC ON / OFF Version 03 .0 0 A

01.01 • FRONT PANEL ELEMENTS Version 12 .9 9 A

01.01.1 • DESCRIPTION OF DISPLAY Version 03 .0 0 A

01.01.2 • TEMPERATURE DISPLAY Version 03 .0 0 A

01.01.3 • OPERATING KEYS Version 12 .9 9 A

01.02 • LIST OF INPUT / OUTPUT SIGNALS Version 12 .9 9 A

02. OPERATIONAL FUNCTIONS Version 03.00 A

02.00 • OPERATIONAL FUNCTIONS - GENERAL Version 12 .9 9 A

02.01 • DOSING Version 03 .0 0 A

02.01.1 • DOSING VOLUME (DATA SHEET) Version 12 .9 9 A

02.01.2 • DOSING VOLUME – NEW / CORRECTION Version 03 .0 0 A

02.02 • INTERFACE: WESTOMAT ® - DCM Version 12 .9 9 A

02.03 • FURNACE FILLING LEVEL INDICATION Version 03 .0 0 B

02.04 • FURNACE HEATING Version 03 .0 0 B

02.05 • OPERATING MODES Version 03 .0 0 A

03. OPERATOR INTERFACE Version 12.99 A

03.00 • STRUCTURE OF OPERATOR INTERFACE Version 12 .9 9 A

04. DOSING OPERATION (ON / OFF) Version 03.00 A

04.00 • SWITCHING DOS ON- / OFF - GENERAL Version 03 .0 0 A

04.01 • SWITCHING MANUAL DOS ON / OFF Version 03 .0 0 A

04.02 • SWITCHING AUTO DOS ON / OFF Version 12 .9 9 A

05. DISTURBANCES Version 03.00 A

05.00 • DISTURBANCES - GENERAL Version 03 .0 0 A

05.01 • STATUS DISTURBANCES Version 03 .0 0 B

05.02 • PROCESS DISTURBANCES AT WESTOMAT ® Version 03 .0 0 A

05.03 • PROCESS DISTURBANCES AT DCM Version 03 .0 0 A


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CONTENTSWESTOMAT ProDos

DPC

OPERATING MANUAL

00.00 2 - 2 0000-B.doc Version: 03.00 B DOSING CONTROL

06. HELP FUNCTIONS Version 03 .0 0 A

06.00 •

GENERAL DESCRIPTION Version 12 .9 9 A06.01 • ERROR HISTORY Version 03 .0 0 B

06.02 • INPUT / OUTPUT LEVEL Version 12 .9 9 A

06.03 • CYCLE COUNTERS Version 12 .9 9 B

06.04 • DATA DISPLAY Version 03 .0 0 B

06.05 • i / T (INFO - TEMPERATURES ) Version 12 .9 9 A

06.06 • / T (INPUT TEMPERATURE VALUES) Version 12 .9 9 A

06.07 • PRINTER Version 03 .0 0 B

06.08 • MEMO . Version 12 .9 9 A

07. SETUP MODE Version 03 .0 0 B

07.00 GENERAL INSTRUCTIONS Version 03 .0 0 B

07.01 • LDT: LANGUAGE / DATE / TIME Version 03 .0 0 B

07.02 • LOG DATA Version 03 .0 0 B

07.03 • REGULATOR-HEATING (GENERAL) Version 03 .0 0 B

07.03.1 • REGULATOR CONFIGURATION Version 03 .0 0 B

07.03.2 • TEMPERATURE REDUCTION Version 03 .0 0 B

07.03.3 • FIRST WARM-UP Version 03 .0 0 B

07.04 • FILLING LEVEL INDICATION - GENERAL Version 03 .0 0 B

07.04.1 • DISPLAY MODE Version 03 .0 0 B

07.04.2 • SWITCHING THRESHOLD (of lamps) Version 03 .0 0 B

07.04.3 • CELL-FILLING LEVEL SYSTEM - GENERAL Version 03 .0 0 A

07.04.3.1 • DATA ENTRY . Version 03 .0 0 A

07.04.3.2 • CELL-mA-SIGNAL Version 03 .0 0 B

07.04.3.3 • CELL - P/t-MIN-MEASURING Version 03 .0 0 B

07.04.3.4 • SIGNAL COMPENSATION . Version 03 .0 0 B

07.04.4 • HPDE-FILLING LEVEL SYSTEM - GENERAL Version 03 .0 0 B

07.04.4.1 • DATA ENTRY Version 03 .0 0 B

07.04.4.2 • HPDE - P/t-MIN-MEASURING Version 03 .0 0 B

07.05 • kg-DIAGRAM Version 03 .0 0 B

07.05.1 • REFERENCE-(DOSING)-VOLUMES RDV Version 03 .0 0 B

07.05.2 • OPERATING DATA Version 03 .0 0 B


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWARE

DOSING CONTROL 0100-B.doc Version: 03.00 A 1 - 4

ProDos® DPC - WESTOMAT® CONTROLSYSTEM

01.00

The ProDos® DPC control is a compact,microprocessor-controlled digital system for theprocess control and process regulation, operation andvisualisation of the WESTOMAT® the automatic dosingsystem designed for the dosing of aluminium melt.

The system's CPU consists of heavy-duty industrialelectronic elements and can be integrated in the frontpanel of the switch cabinet door. The CPU is equippedwith:

• integrated power supply unit for the supply with230V AC and battery buffer to protect savedprogramme parameters against loss.

• integrated digital input and output modules

• integrated analog modules for the control of aproportional valve including interfaces for pressuremeasuring converter and NiCrNi thermocouples

• integrated temperature regulator for temperatureholding operation of the furnace

• pluggable terminals for all electric connections

• data transmission interface for remove diagnosis(by means of printer, PC, modem …) for thereading of process data and set-up parameters

• data transmission interface for the loading of software

• protective cover at the rear side

• front panel, suitable for die-casting environment,including:

• back-lit LC display for the visualisation andoperator guidance by means of text in selectedlanguage

• eight-segment display of desired and actualmelt temperature

• numerical keyboard

• five multi-function keys (below display ; theavailable functions are shown in the respectivetext fields of the display)

• eight help menu keys (availability indicated byLEDs)

The ProDos® DPC is equipped with the followingoperational functions:

• DOSING TECHNIQUE:

• Furnace pressure control system withproportional inlet valve and measuring pressureconverter


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HARDWARE

ProDos DPC - the WESTOMAT ControlSystem

WESTOMAT ProDos DPC

OPERATING MANUAL

01.00 2 - 4 0100-B.doc Version: 03.00 A DOSING CONTROL

• Integral calculation of the dosing process for accurate definition of dosing volumes and

repeated processing

• Options for dosing contact (DC): by means of sensing electrode or pneumatic contactor (PneuCo) at the outlet of the dosing pipe

• Input menu for adjustment of dosing volume

• Modification menu for selective modifications of dosing data.

• CONTROL TECHNOLOGY:

• Proven and standardised signal interfacebetween WESTOMAT® dosing unit and die-casting machine (DCM) for save, monitored and

coordinated processing

• Automatic opt imisation system for cyclesynchronisation of WESTOMAT® processes withclosing movement of DCM-die, reducing cycletime per cast (t9 = cast time of DCM).

• TEMPERATURE REGULATION SYSTEM:

• Temperature monitoring by means of thermocouple in melt and regulation of holdingtemperature with automatic switching of furnaceheating

• Monitoring of parameter-controlled quali ty

thresholds of holding temperature fore melt withdosing lock

• Monitoring of parameter-controlled limit valuesfor HEATING ALARM – to prevent solidificationor overheating of melt

• Monitoring of furnace temperature

• EMERGENCY HEATING programme, to be usedin the event of defect in melt thermocouple

• Programmable weekend temperature reductionfor melt

• Automatic warm-up programme for cold start of furnace.

• FURNACE FILLING LEVEL INDICATION:

• Filling level scanning options: by means of loadcell (CELL) or hydraulic-pneumatic pressuredetection system (HPDE)

• Five indicator lamps, which can be programmedto indicate various filling levels and thresholds.


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWARE

ProDos DPC - the WESTOMAT Control System

DOSING CONTROL 0100-B.doc Version: 03.00 A 3 - 4 01.00

• SETUP PROGRAMME:

• To be used during commissioning and for theentry of unit-specific operating parameters:

• LOG data of all setup procedures withautomatic date registration

• Setup of temperature regulators with plant-specific parameters

• Setup of filling level indication and rate of furnace chamber pressure rise for dosing

• Setup for dosing-pipe specific data, e.g.dosing volume range between smallest andlargest possible dosing volume

• Setup of time, date and language of user interface.

ATTENTION

• SETTINGS MAY ONLY BE MADE BY QUALIFIED AND SPECIFICALLY TRAINED STAFF

• ALWAYS COMPLY WITH SAFETYINSTRUCTIONS IN THE OPERATING MANUAL

• The SETUP mode can be protected againstunauthorised manipulation by a code lock withcustomer-specific SETUP CODE LOCK NUMBER:

• SETUP PROGRAMME:

• Setup for selection of operating modes for dosing and heating.

ATTENTION

• THESE SETTINGS MAY ONLY BE MADE BYQUALIFIED AND SPECIFICALLY TRAINED STAFF

• ALWAYS COMPLY WITH SAFETYINSTRUCTIONS IN THE OPERATING MANUAL

• The SETUP mode can be protected againstunauthorised manipulation by a code lock withcustomer-specific OPERATING MODE CODELOCK NUMBER:

• HELP FUNCTIONS:

• Error history - display of the last fifty error eventwith time, date and error message

• Input/output level - display of the switchingstatus and simulation of the output status, of special use for testing and diagnosis

• Cycle counters

• Display of all measured process values, logdata and StrikoWestofen service telephonenumbers.

• Information on temperatures - display of actualand nominal furnace temperatures


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HARDWARE

ProDos DPC - the WESTOMAT ControlSystem

WESTOMAT ProDos DPC

OPERATING MANUAL


• Entry in °C (°F) of nominal value and qualitylimit value (undertemperature/overtemperature)

for melt temperature

• Activation of data output interfaces for individualprocess data (dosing data, disturbances, log,regulator configuration) or output of entiredosing process data log

• MEMO - key for saving data in setup mode


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWARE


SWITCHING ProDos ® DPC ON / OFF 01.00.1

***BASIC STATUS***DOS. PIPE ∅65/21mm

10.03.0013:34:57

HEATINGSCAN=CELL

EXT-KEY DOS-ON or F5 = DOSING !

***** WESTOMAT - DOSING CONTROL *****

P r o D o s

DPC-V1.01-05 = DIE-CASTING-VERSION03.03.00 = DATE OF SETUP DATA

AVAILABLE = 1040 kg MELT

INFO SETUP OPERAT.MODES

kg-DOS:NEW DOSING

F 1 F 2 F 3 F 4 F 5

***BASIC STATUS***DOS. PIPE ∅65/21mm 10.03.0013:34:57 HEATINGSCAN=CELL

F4 = kg-DOS: NEW !


P r o D o s




kg-DOS:NEW DOSING

F 1 F 2 F 3 F 4 F 5

The ProDos® DPC is switched ON and OFF by meansof the main switch at the WESTOMAT switch

cabinet.

SWITCHING ONBy activating the main switch, power (230V AC - 50/60Hz) is supplied to the CPU is and the followingprocesses take place:

• Automatic loading of the saved setup data(protected against data loss by buffer battery) to

the RAM of the ProDos® DPC

• After completion of loading (i.e. after approx. 8 to

10 sec.), the ProDos® DPC is in BASIC STATUSand, depending on the WESTOMAT equipment,

the following operational functions are active or available:

• FURNACE HEATING is available:

- if the temperature control is carried out by means

of the internal regulator of the ProDos® DPC(HEATING - see display field right top corner)

• FURNACE LEVEL INDICATION is active:

- if the fill level indication is carried out bymeans of a load cell (SCAN=CELL - see displayfield right top corner)

• DOSING OPERATION is available:

- see text (EXT. KEY DOS-ON or F5 = DOSING!) in the info line of the display

• MULTI-FUNCTION KEYS (F1 to F5) areavailable:

- see respective function descriptions in theassociated display fields

• HELP MENU KEYS are available:

- see Chapter 06 of the Operating Manual.

ATTENTION

The BASIC STATUS of the ProDos® DPC is notfully completed:

• if no entry of a dosing volume has been madeand saved in the main memory:- see text in info line.


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HARDWARE

SWITCHING ProDos DPC ON / OFF

WESTOMAT ProDos DPC

OPERATING MANUAL

01.00.1 2 - 2 01001-B.doc Version: 03.00 A DOSING CONTROL

ATTENTION

The BASIC STATUS of the ProDos® DPC is notdisplayed if the settings previously entered in setup

mode are not completed and saved in the mainmemory - e.g.:

• setup mode for kg-DIAGRAM not completed andsaved in the main memory:

- see text in info line.

SWITCHING OFF

By switching off the main switch at the WESTOMAT

switch cabinet, the power supply (230V AC - 50/60 Hz)to the CPU disconnected:

• All operational functions of the ProDos® DPC areswitched off

• All entered and saved data and settings for OPERATING MODES are saved in the main

memory of the ProDos® DPC (protected againstdata loss by buffer battery).

ATTENTION

By switching off the main switch at the

WESTOMAT switch cabinet, the furnace heatingis also switched off. Idle times of more than approx.6 hours result in:

• Cooling of the furnace chamber

• Solidification of the residual melt in the furnace

• Damage to the ceramic parts immersed in themelt

SETUP MODE: 10.03.0013:34:57

HEATINGSCAN=CELL

F4 = kg-DIAGRAM !

SETUP of OPERATING DATA for:F1: LOG DATA ...................... = 1F2: FILL LEVEL INDICATION ......... = 1F3: LDT - LANGUAGE/DATE/TIME ...... = 1F4: kg-DIAGRAM .................... = 0F5: REGULATOR DATA and HEAT-FUNCT.. = 1

LOGDATA

FILLLEVEL

LDTSETUP

kg-DIA-GRAM

REGULAT.HEATING

F 1 F 2 F 3 F 4 F 5


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWARE

DOSING CONTROL 0101-A.doc Version: 12.99 A 1 - 2

`

FRONT PANEL ELEMENTS 01.01

The ProDos® DPC is designed as a front panel deviceand integrated in the switch cabinet door. The frontpanel is secured on the switch cabinet door by meansof screws and a frame seal.

The front panel includes a visualisation field and theoperating elements of the system:

• Keyboard with eight keys of the help menu:

- see chapters 01.01.3 and 06.00

• Four arrow-keys to move the cursor in thevisualisation field of the display:

- see chapter 01.01.3.

• a numeric keyboard for the entry of (numerical)data:

- see chapter 01.01.3

• Row of five multi-function keys (F1 to F5); thecurrent functions of the keys are displayed in thecorresponding display fields:


• Segmented display of the actual and desired melttemperature:


• Back-lit display:



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HARDWARE

FRONT PANEL ELEMENTS

WESTOMAT ProDos DPC

OPERATING MANUAL

01.01 2 - 2 0101-A.doc Version: 12.99 A DOSING CONTROL

blank page


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWAREFRONT PANEL ELEMENTS


DESCRIPTION OF DISPLAY 01.01.1

***BASIC STATUS***DOS. PIPE ∅ 100/35mm

10.03.0013:34:57

HEATINGSCAN=CELL



P r o D o s




kg-DOS:NEW DOSING

F 1 F 2 F 3 F 4 F 5


OFFLINE: 27.65kgDOS. PIPE ∅ 100/35mm

SETUP MODE:LOG DATA

10.03.0013:34:57

AUTOSCAN=CELL

The display of the ProDos®

DPC is separated intoseveral display fields. Their contents vary according tothe current status.

Example for the display in BASIC STATUS, after:

• setup of:

• LDT - Language / Date / Time (clock)

• the LOG DATA

• the FILLING LEVEL INDICATION

• the kg-DIAGRAM

• the REGULATOR CONFIG. (temp. regulator)

is completed, and:

• a DOSING VOLUME and

• the OPERATING MODES:• TOP-STOP

• SYNCHRONIZATION

• WEEK-END REDUCTION TEMPERATURE

• EMERGENCY HEATING

have been set and saved.

DISPLAY FIELDS - Examples and EXPLANATIONS

The control is in BASIC STATUS mode:

• First line: BASIC STATUS

• Second line: Size of pipe used in the currentdosing operation.

The control is in F5 STATUS or in DOSING STATUS:

• First line: entered and saved dosing volume

• Second line: Size of pipe used in the currentdosing operation.

The control is in SETUP MODE:

• First line: SETUP MODE

• Second line: according to the modified set-upmode.

The control is in BASIC STATUS or in F5 STATUS:

• First line: current date

• Second line: current time

The control is in AUTO DOSING STATUS:

• First line:current operating mode•

• Second line: furnace fill level indication by meansof pressure-load weighing cell (CELL) is active.


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DESCRIPTION OF DISPLAY

WESTOMAT ProDos DPC

OPERATING MANUAL


The control is in MANUAL DOSING STATUS:

• First line: current operating mode

• Second line: furnace filling level indication viahydraulic-pneumatic pressure detection (HPDE) is

active.


• First line: temp. regulation of furnace heating viainternal regulator is active

• Second line: furnace fill level indication by meansof pressure-load weighing cell (CELL) is active.


• First line: temp. regulation of furnace heating viaexternal regulator is active

• Second line: furnace filling level indication viahydraulic-pneumatic pressure detection (HPDE) isactive.

The control is in MANUAL STATUS or in AUTODOSING STATUS:

• First line: dosing operation is entered

• Second line: Stand-by for dosing is ... ON, ... ENDor furnace doses = ... RUN.

INFO LINE

This line of the display shows important messages for

the operator, for example:

• The control is in BASIC STATUS; for dosing, pressexternal LED-key DOS-ON (installed at the switchcabinet door or at the control panel), or press multi-function key F5 and then follow the instructions

• The control is in F5 STATUS and theEMERGENCY STOP key of the die-cast machine(DCM) control is activated

• The control is in DOSING STATUS or F5 STATUSand the query result of the DCM signals returnedan incorrect position of the press plunger

• the query result of the WESTOMAT stand-by for dosing returned an incorrect status - the selectedoperating mode TOP-STOP is not activated

• the WESTOMAT and DCM are in stand-by for MANUAL DOSING (in MANUAL)

• in the AUTO-DOS operating mode, comments areonly displayed in the event of errors.

MANUALSCAN=HPDE

HEATINGSCAN=CELL

SCAN=HPDE

DOSING... ON

EXT. KEY DOS-ON or F5 = DOSING !

ERROR: EMERGENCY STOP DCM / ESC=back

Position error: I-24=0 / ESC=back

Position error: TOP-STOP / ESC=back

DOSING by HAND = READY

EXT. KEY DOS-ON or F5 = DOSING !


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WESTOMAT ProDos DPC

OPERATING MANUAL



DOSING CONTROL 01011-B.doc Version: 03.00 A 3 - 4 01.01.1


P r o D o s

DPC-V1.01-05 = DIE-CAST-VERSION03.03.00 = DATE OF SETUP DATA


kg-DOS-RANGE: 12.50 to 22.35 kg

17.65 kg = dosing volume (OFFLINE)+ 0.75 kg = AUTO-increase up to 3.27- 1.15 kg = AUTO-decrease up to 3.25- 55.0 % = furnace chamber-CORRECTION

1.8 s = t5 - lag timeP-FD = 80 mbar / t4 = 3.55 s

F1 - SAVE DATA MODIFICATION

F3 – DO NOT SAVE DATA MODIFICATIONKEEP DATA UNMODIFIED

F5 - BACK TO ENTRY

Instruction for AUTO-DOSING:- switch DCM into AUTO !

Instruction for MANUAL DOSING:- CLOSE DCM-DIE in position MANUAL

completely !

t6 t7

t2 t3 t4 t5

DCTS=

DCM-DIE

WESTOMAT: AVAILABLE = 890 kg MELT

DCM-DIE

t6 t7

t2 t3 t4 t5t1

t8

p = 57.49 mb NC = 12725 AC =

t9 DCTS=

COMMENT AND VISUALISATION FIELD

Depending on the current operating mode, this fielddisplays detailed operating instructions or shows the

dosing process (visualisation of the DCM signals andindividual dosing steps):

• The control is in BASIC STATUS:

the DPC-V .... software version, the set-up dataand the available residual melt in the furnaceare displayed

• Form for the entry or modification of individualparameters of a dosing volume file (kg-DOS: NEW)

• Instruction displayed prior to saving a new entry

• Instructions regarding DCM

• Visualisation diagram - WESTOMAT® and DCM-DIE are ready for MANUAL DOSING

• Visualisation diagram - Process of WESTOMAT®

AUTO-DOSING operation


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WESTOMAT ProDos DPC

OPERATING MANUAL


DESCRIPTION OF MULTI-FUNCTION KEYS

The functions of the multi-function keys installed belowthe display change according to the selected operating

mode - Examples:

• The control is in BASIC STATUS. The keyfunctions are as follows:

• F1 call up INFO

• F2 call up SETUP MODE for

• F3 call up OPERATING MODES

• F4 call up entry for a new dosing volume

• F5 initiate query for ready for dosing of theWESTOMAT and the DCM-DIE

• the SETUP MODE has been selected; continue

with keys:• F1 - to DATA LOG

• F2 - to FILL LEVEL INDICATION

• F3 - to LDT = Language / Date / Time

• F4 - to kg-DIAGRAM

• F5 - to REGULATOR HEATING

• After entry of new values, the MEMO has beenpressed; continue with keys:

• F1 = save

• F3 = do not save

• F5 = back to data entry

• The control is in DOSING STATUS; continue withkeys:

• F1 displays operator INFO

• F3 allows for the modification (correction) of dosing parameters

DISPLAY ILLUMINATION

In order to protect the screen, the display illuminationis automatically switched off. It can be switched on bypressing any key.

The brightness of the display can be adjustedcontinuously by means of the following keys:

• hold . and key - or +or:

• press and hold ± and hold - or +.


kg-DOS:NEW DOSING

F 1 F 2 F 3 F 4 F 5

LOGDATA

FILLLEVEL

LDT-SETUP

kg-DIA-GRAM

REGULAT.HEATING

F 1 F 2 F 3 F 4 F 5

MEMO= YES

MEMO= NO

BACK TOENTRY

F 1 F 2 F 3 F 4 F 5

INFO MODIFYDATA

F 1 F 2 F 3 F 4 F 5


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WESTOMAT ProDos DPC

OPERATING MANUAL



TEMPERATURE DISPLAY 01.01.2

X

W

6 9 5

6 9 4

The ProDos ® DPC front panel is equipped with asegmented digital display for the temperature of themelt. The selection of an internal or external regulator as well as the display in °C or in °F is made in the logof the control.

This display is only available if an internal temperatureregulator is selected:

• X = current ACTUAL VALUE of melt temperature

• W = DESIRED VALUE of melt temperature.

ATTENTION

In the event of an ERROR: HEATING ALRAM: both

displays (X and W) are blinking.

If the EMERGENCY HEATING mode is selected, X= current ACTUAL VALUE of the melt temperatureis blinking and the displayed value does notcorrespond to the actual value.

In the event of failure of the thermocouple(ERROR: HEATING ALARM) the displayedtemperature value does not correspond with theactual value.


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TEMPERATURE DISPLAY

WESTOMAT ProDos DPC

OPERATING MANUAL


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WESTOMAT ProDos DPC

OPERATING MANUAL



OPERATING KEYS 01.01.3

The ProDos® DPC is equipped with the followingoperating keys at the front panel:

• NUMERICAL KEYBOARD with the following keyfunctions:

• Input keys 0 to 9 and .

• Key ± for the entry of positive/negativevalues

•

Keys + and - , together with key .for the adjustment of the brightness of thedisplay

• Key ESC to exit the current menu

and return to BASIC STATUS

• Key CLR for deleting an entry (prior topressing

ENTER)

• Key = ENTER to confirm an entry

• Key / is currently not used

• Key * is currently not used.

• Five MULTI-FUNCTION KEYS, located below thedisplay, with various functions:

• The functions of key F1 to F5 dependon:

- current operating mode of the control;

- The current function of each key is displayedin the respective display field located above thekey (no text = no function).


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OPERATING KEYS

WESTOMAT ProDos DPC

OPERATING MANUAL

01.01.3 2 - 4 01013-A.doc Version: 12.99 A DOSING CONTROL

• HELP MENU KEYS (with LEDs) to access the

HELP FUNCTIONS of the ProDos® DPC:- see chapter 06.00

• Key ERROR HISTORY to activate

the ERROR HISTORY help function - display of error list

- see chapter 06.01

• Key I / O LEVEL to activate

the following help functions:

SET DIG-OUT

- WESTOMAT-DCM SIGNALS- display

- DIGITAL IN / OUT - display

- ANALOG IN / OUT - display

- see chapter 06.02

• Key CYCLE COUNTER to activate


- Display and delete total and shift cycle counter of injections and errors

- see chapter 06.03

• Key DATA DISPLAY to activate


- CYCLE DATA – display data table

- SETUP DATA - display data table

- see chapter 06.04

• Key i / T to activate the

help function

- Display of table of ACTUAL VALUES /NOMINAL VALUES of the temperature holdingoperation:

- of the melt

- in the furnace chamber

- operating hour counter of the heating

- see chapter 06.05


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WESTOMAT ProDos DPC

OPERATING MANUAL


OPERATING KEYS

DOSING CONTROL 01013-A.doc Version: 12.99 A 3 - 4 01.01.3

• Key ° / T to activate the

help function

- Entry of operating values of the holdingtemperature of the melt:

- NOMINAL VALUE MELT

- UNDERTEMPERATURE MELT

- OVERTEMPERATURE MELT

- see chapter 06.06

• key PRINT to activate

the help functions for data output to thePRINTER interface:

• INDIVIDUAL OUTPUT of:

- DOSING DATA HISTORY

- ERROR HISTORY

- LOG DATA

- REGULATOR CONFIGURATION

• CYCLICAL / CONTINUOUS output of:

- CYCLIC DOSING DATA

- CYCLIC QUALITY DATA- CYCLIC MEASURING VALUES (for PC)

- see chapter 06.07

• Key MEMO to save

entries and settings.

- see chapter 06.08.

• four ARROW KEYS to move the cursor in thevisualization field:

- up, down, left and right.


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OPERATING KEYS

WESTOMAT ProDos DPC

OPERATING MANUAL


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WESTOMAT ProDos DPC

OPERATING MANUAL

HARDWARE


LIST OF INPUT / OUTPUT SIGNALS 01.02

I-NO. I = DIGITAL INPUT SIGNALS

PLUG CONNECTOR TERMINAL

NO.

I-01 • dosing contact ................................ (minus-switching) TB2. P2 6

I-02 • EMERGENCY STOP by WESTOMAT 5

I-03 • EMERGENCY STOP by DCM 10

I-04 • undertemperature melt ........... (with external regulator) 9

I-05 • overtemperature melt ............. (with external regulator) 14

I-06 • cleaning door locked 13

I-07 • pressure switch furnace chamber 18

I-08 • dosing ON 17

I-09 • furnace ready for injection TB2. P3 6

I-10 • dosing by hand 5

I-11 • acknowledge disturbance 10

I-12 • acknowledge horn 9

I-13 • n/a 14

I-14 • refill cover OPEN 13

I-15 • heating ON 18

I-16 • monitoring PneuCo 17

I-17 • auto-fill test • DCM TB2. P4 6

I-18 • auto-operation ON • DCM 5

I-19 • die closing • DCM 10

I-20 • die closed 1 • DCM 9I-21 • die closed 2 • DCM 14

I-22 • die ready for injection 1 • DCM 13

I-23 • die ready for injection 2 • DCM 18

I-24 • plunger in back position • DCM 17

I-25 • discontinue synchro. operation • DCM TB2. P5 6

I-26 • kg-reduction • DCM 5

I-27 • kg-increase • DCM 10

I-28 • n/a 9

I-29 • n/a 14

I-30 • n/a 13I-31 • n/a 18

I-32 • n/a 17

AI-NO. AI = ANALOG INPUT SIGNALSPLUG CONNECTOR + TERMINAL -

NO.

AI-01 • mV-NiCrNi: thermocouple melt TB2. P4 6 / 4

AI-02 • mV-NiCrNi: thermocouple furnace chamber 9 / 7

AI-03 • 4 to 20 mA: furnace chamber measuring pressureconverter (30 V DC )

1 / 3

AI-04 • 4 to 20 mA: load cell ................................. (30 V DC) 4 / 6


24/288

HARDWARE

LIST OF INPUT / OUTPUT SI GNALSWESTOMAT ProDos DPC

OPERATING MANUAL


O-NO. O = DIGITAL OUTPUT SIGNALS Ampere

LOADPLUG CONNECTOR TERMINAL

NO.

O-01 • general disturbance .......... (collective relay) 0,5 TB3. P2 2

O-02 • horn 0,5 6

O-03 • solenoid-lock - door locking 0,5 10

O-04 • fill furnace ................... (for melting house) 0,5 14

O-05 • CPU enabled for dosing operation ON 0,5 TB3. P2 1

O-06 • test mode 0,5 5

O-07 • n/a 0,5 9

O-08 • ALARM heating 0,5 13

O-09 • metal supply in automatic • DCM 0,5 TB3. P3 2

O-10 • Metal filling in active • DCM 0,5 6O-11 • release for injection 1 • DCM 0,5 10

O-12 • release for injection 2 • DCM 0,5 14

O-13 • disturbance metal supply • DCM 0,5 TB3. P3 1

O-14 • ready for dosing ON • DCM 0,5 5

O-15 • n/a 0,5 9

O-16 • n/a 0,5 13

O-17 • lamp - furnace filling level (FULL) 0,5 TB3. P4 2

O-18 • lamp - furnace filling level (92% = standard) 0,5 6



O-21 • lamp - furnace filling level (23% = standard) 0,5 TB3. P4 1

O-22 • lamp - ready for operation MANU/AUTO 0,5 5

O-23 • lamp - dosing operation 0,5 9

O-24 • lamp - disturbance 0,5 13

O-25 • EMERGENCY STOP - pressurised air inletvalve spool

2 TB3. P5 1

O-26 • EMERGENCY STOP - deaeration pilot valvespool

2 3

O-27 • valve spool - dosing pipe scanning 2 5

O-28 • deaeration pilot valve spool 2 7

O-29 • bypass valve spool .... (intake press. air from DC ) 2 TB3. P6 1

O-30 • n/a 2 3

O-31 • heating stage 1 .......................... (full load) 2 5

O-32 • heating stage 2 ...................... (partial load) 2 7

AO-NO. AO = ANALO G O UTPUT SIGNALS SIGNALPLUG CONNECTOR + TERMINAL -

NO.

AO-01 • analog signal for prop. valve pressure air inlet 0 to 10 V TB1. P4 1 / 3


25/288

WESTOMAT ProDos DPC

OPERATING MANUAL

OPERATIONAL FUNCTIONS


OPERATIONAL FUNCTIONS - GENERAL 02.00

The ProDos® DPC WESTOMAT® control is equipped

with a range of programme options.


Operational functions include all functions thatcommunicate with the WESTOMAT® and itsenvironment via input/output connections:

• Operational function DOSING:- see chapter 02.01

• Process regulation and control of the cyclicrelease of a defined quantity of aluminium meltto the DCM, including automated additionaloptions:

• Dosing with or without TOP-STOP• Dosing with electrode or PneuCo

• Dosing volume REDUCTION

• Dosing volume INCREASE

• Operational function DCM-INTERFACE:- see chapter 02.02

• Coordination of the processes of theWESTOMAT® and DCM, including automaticsynchronization and processing of special DCMfunctions:

• Quick tension test

• Tension control during die closing

• Automatic dosing volume REDUCTION

• Automatic dosing volume INCREASE

• Operational function FILLING LEVEL INDICATION:- see chapter 02.03

• Detection and indication of furnace filling levelincluding min. limit level monitoring andsignalling for refilling; filling level detection bymeans of:

• load cell (CELL)

• hydraulic-pneumatic pressure detection deviceHPDE (without CELL).

• Operational function HEATING:

- see chapter 02.04• Full load/partial load OFF of furnace heating;

temperature regulation and monitoring of the meltand furnace chamber temperature by means of:

• Dosing-lock at undertemperature or overtemperature of the melt

• First warm-up (cold start) of the furnace

• Timer programme for weekend reduction of themelt temperature.


26/288


OPERATIONAL FUNCTIONS - GENERALWESTOMAT ProDos DPC

OPERATING MANUAL


• Operational function OPERATING MODES for dosing and heating:- see chapter 02.05

• Dosing with or without TOP-STOP• Dosing with or without synchronization

• Weekend reduction of melt temperature

• EMERGENCY HEATING (without meltthermocouple).

• Operational HELP FUNCTIONS:- see chapters 06.00 to 06.08

• Error history

• I/O level

• Cycle counter

• Data display

• INFO of temperatures

• Entry of nominal values (melt temperature)

• Print• MEMO (saving).

• Operational function SETUP MODE:

• At commissioning, the ProDos® DPC isconfigured with WESTOMAT® data and theprogrammed setup procedures:- see chapter 07.00

• Setting time and date, selection languageand software version- see chapter 07.01

• Log data:- see chapter 07.02

• Entry of parameters

• Inclusion and exclusion of functions:

• Electrode or PneuCo

• Internal or external temp. regulator

• Temperature display in °C or °F

• Filling level monitoring with CELL or HPDE

• Heating regulator and regulator configurationparameters:- see chapters 07.03 + 07.03.1 + 07.02.2

• data for EMERGENCY HEATING

• Temperature reduction

• Selection of warm-up programme for

furnace cold start

• Fill level indication with:- see chapters 07.04+ 07.05

• thresholds for FULL and EMPTY

• Display mode of filling level lamps

• Standard or customer-specific switchingthresholds of filling level lamps

• Pressure and time values of dosingcontact and max. pressure ramp duringdosing

• kg-diagram of dosing volume range:- see chapter 07.06

• for dosing pipe 1

• for dosing pipe 2


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WESTOMAT ProDos DPC

OPERATING MANUAL



DOSING 02.01

SETUP MODE:LOG DATA

10.03.0013:34:42

HEATINGSCAN=CELL

↑ ↓, INPUT, ENTER and MEMO / ESC=back

K02. DOSING CONTACT (DC) WITH:

1 = (Electrode = 1 / PneuCo = 0)

2.5 s = t5-DC (DC after deaeration)

INFODOSING

The operational function DOSING describes thepreparation for dosing and the DOSING processes of

the ProDos® DPC in connection with the DCM.

PREPARATIONS

Prior to the commencement of the dosing operation,the following settings must be completed at the

ProDos® DPC:

• Entry of DOSING VOLUME (in kg and according to thecast incl. sprue) - see chapter 02.01.2 for additionalparameters:

• with / without dosing volume INCREASE

• with / without dosing volume REDUCTION

• Transfer of % value of FURNACE CHAMBERCORRECTION - adjustment is required, if thedosing volume is continuously increased or reduced when the furnace is gradually emptied.

• Transfer of sec value of t5 LAG TIME -adjustment is required if the inclination or lengthof the channel has been altered.

• Selection of OPERATING MODES - see chapter 02.05:

• Operating mode with / without TOP-STOP

• Operating mode with / without LEVEL-SCANNING

• Operating mode with / withoutSYNCHRONIZATION

• Standard - with SYNCHRONIZATION untilDIE CLOSED

• Exceptions (e.g. three-plate die) - withSYNCHRONIZATION until DIE READY FORINJECTION.

• Selection of OPERATING OPTIONS, selectable insetup mode LOG K02 - see chapter 07.02:

• Operation with ELECTRODE:

• This option is independent of the switchingmode (AUTO / MANUAL)

• Dosing contact (DC) with the melt in thedosing pipe by means of an electrodeattached to the dosing pipe

• During the metal feed process, this electrodeis retracted from the melt area.


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DOSINGWESTOMAT ProDos DPC

OPERATING MANUAL


• Operation with PneuCo:

• This option is independent of the switchingmode (AUTO / MANUAL)

• Dosing contact (DC) with the melt in thedosing pipe by means of the automaticclosing of the PneuCo nozzle (pneumaticcontact) in the dosing pipe.

• During the metal feed process, the PneuCopressure prevents the melt from penetratinginto this nozzle

ATTENTION

The availability of these options depends on theequipment of the WESTOMAT®.

In addition to the selection of the options in the log,the hardware switch in the switch cabinet must beset to the appropriate position.

• Activation of SWITCHING MODES by means of selecting switch position at DCM:

• Switching mode MANUAL - if I-18 = 0, DCMcontrol not set to AUTO (or semi-AUTO) - seechapter 04.01

• Switching mode AUTO - if I-18 = 1, DCM controlset to AUTO (or semi-AUTO) - see chapter 04.02

• Dosing process (in AUTO-ASYNCHRON)activated

• At open DCM die, the plunger is once fullymoved forward and back into end position.

• DCM die is open.

PROCESSES and VISUALISATION

The display field of the ProDos® DPC shows theprocesses of the DCM die and the dosing process.

DCM die - Process sequence according to interfacesignals:

• Plunger not in back position (I-24 = 0)

• Plunger in back position (I-24 = 1)

SETUP MODE:LOG DATA

10.03.0013:34:42

HEATINGSCAN=CELL


K02. DOSING CONTACT (DC) WITH:

0 = (Electrode = 1 / PneuCo = 0)

2.5 s = t5-DC (DC after deaeration)

INFODOSING

OFFLINE: 27.65kgDOS. PIPE:∅100/35mm

MANUALSCAN=CELL

DOSING... END

instruction / EXT.-KEY DOS-OFF

Instruction for AUTO-DOSING:- Set DCM into AUTO !

Instruction for MANUAL DOSING:- CLOSE DCM-DIE in position MANUAL!

completely !

INFO MODIFYDATA DOSING

OFFLINE: 7.65kgDOS. PIPE: ∅80/24mm

AUTOSCAN=CELL

DOSING... ON

DCM-DIEt6 t7

t2 t3 t4 t5

DCt9TS=

t8

WESTOMAT: AVAILABLE = 890 kg MELTINFO MODIFY

DATA DOSING

DCM-DIEt6 t7 t8

DCM-DIEt6 t7 t8


29/288

WESTOMAT ProDos DPC

OPERATING MANUAL


DOSING


DCM-DIEt6 t7 t8

DCM-DIEt6 t7 t8

DCM-DIEt6 t7 t8

OFFLINE: 7.65kg

DOS. PIPE: ∅ 80/24mm

AUTO

SCAN=CELL

DOSING

... ON

t2 t3 t4 t5t1

t9 DC

DCM-DIE

t6 t7 t8

TS=



DCM-DIEt6 t7 t8

t2 t3 t4 t5t1

t9 DC

p= 29.12 mb nc= 6379 ac=

TS=

t2 t3 t4 t5t1

t9 DC

p= 29.82 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 29.82 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

• Die closing (I-19 = 1) and plunger in backposition

• Form closed (I-20 + I-21 = 1) and plunger inback position

• Die ready for injection (I-22 + I-23 = 1) andplunger in back position

• DOSING MODE - Sequence of programme steps in AUTO-SYNCHRON operation in connection withclosing process of DCM die:

• The DCM die is ready for injection and the

ProDos®

DPC is properly set to AUTO dosingmode

• ProDos® DPC signals to DCM control:METAL FEED to AUTO - O-09 and DOSINGON - O-14 = 1

• Furnace chamber pressure below thepressure hold for TOP-STOP

• Lamps READY - O-22 = 1

• The synchron. time t1 and the die closingprocess = DIE CLOSES (I-19 = 1) start

simultaneously

ATTENTION

p = current furnace chamber pressurenc = NOMINAL counter of dosing volumeac = ACTUAL counter of dosing volume

• The synchron. time t1 has expired and thepressure ramp to DC (R-DC/TS) is initiated in thefurnace chamber, starting at the TOP-STOPpressure hold level:

• Cycle time t1 recorded

• Dosing status from DOSING ... ON toDOSING ... RUN

• Lamp DOSING OPERATION - O-23 = from 0to 1

• Pressure ramp to DC, signal = DIE CLOSED (I-20 and I-21 = 1) - release of melt to shot sleeve

• DCM cycle time t6 recorded


30/288



OPERATING MANUAL


• At DC, pressure ramp to DOSING (R-DOS), startof metal feed and calculation of ACTUALcounter value for dosing volume:

• Cycle times t2 and t9 recorded

• ProDos® DPC signal to DCM controlMETAL FEED - O-10 = from 0 to 1

• if DC with electrode, it is moved upwards

• During feed pressure rise (or during feed time),the signals for DIE READY FOR INJECTION (I-22 and I-23 = 1) are received, release of meltfor dosing to shot sleeve, DCM awaitingRELEASE FOR INJECTION:

• DCM cycle time t7 recorded

• Feed pressure reached = stop of pressure riseand feed presser holding:


• Start of lag time

• Metal feed with max. pressure

• When ACTUAL counter = NOMINAL counter,start of deaeration (release of furnace chamber pressure):


• Lag time t5 and DC monitoring time t5-DCstarted

• ACTUAL counter continued until end of metal feed

• Lag time t5 has expired and the dosing processis completed. ACTUAL counter is stopped:

• The furnace chamber pressure is reduced

• Test of DC after deaeration has beencarried out and t5-DC is completed

• Dosing status from DOSING ... RUN toDOSING ... END

• Lamp DOSING OPERATION - O-23 = from 1to 0

t2 t3 t4 t5t1

t9 DC

p= 39.32 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 75.42 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 99.42 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 99.37 mb nc= 6379 ac=

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 27.82 mb nc= 6379 ac=6867

DCM-DIE

t6 t7 t8

TS=


31/288

WESTOMAT ProDos DPC

OPERATING MANUAL


DOSING


t2 t3 t4 t5t1

t9 DC

p= 17.34 mb nc= 6379 ac=6867

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 29.84 mb nc= 6379 ac=6867

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

p= 29.84 mb nc= 6379 ac=6867

DCM-DIE

t6 t7 t8

TS=

t2 t3 t4 t5t1

t9 DC

DCM-DIE

t6 t7 t8

TS=


DCM-DIEt6 t7

t2 t3 t4 t5

DCt9TS=

t8

p= 27.82 mb nc= 6379 ac=6867

• Signal to DCM control = RELEASE OFINJECTION - O-11 and O-12 = 1:

• Signal READY FOR INJECTION - I-22

and I-23 = 0

• PLUNGER starts to move, I-24 = 0

• The plunger movement is carried out while thecast solidifies, etc. In the furnace chamber, theholding pressure for TOP-STOP is built up

• The furnace pressure TOP-STOP-hold isreached:

• After solidification, the DCM die is opened, thecast is removed and the die is prepared for newcycle

• Plunger returns to back position - I-24 = from 0to 1:

•

Dosing status from DOSING ... END toDOSING ... ON

• Dosing cycle is completed

• DOSING OPERATION lamp - O-23 = from 0to 1 and WESTOMAT ® ready for next dosingcycle

• The following closing movement (I-19 = from0 to 1) starts the next dosing cycle and thetotal cycle time (t-CYCL) of the previouscycle is recorded.

• in AUTO-ASYNCHRON dosing, thesynchronization time t1 is not displayed:

• The procedure is similar to that of theSYNCHRON cycle, apart from the dosingpressure ramp to DC (R-DC/TS), which startsfrom the pressure level TOP-STOP holdingafter competed closing of DCM-die (I-19 to I-23 = 1).


32/288



OPERATING MANUAL


• MANUAL dosing mode:

• Manual dosing is started by pressing key F5at manual closing of DCM-die (I-19 toI-24 =1).

• Visualization of process as above and withoutsynchron. time t1.

DOSING PROCESS in WESTOMAT®

• with TOP-STOP

The dosing process in the furnace consists of the

following steps:

• PRESSURE START to DOSING CONTACT (DC):

• Pressure ramp R-DC/TS - see value in LOG K08

• DOSING CONTACT (DC) with:

• NOMINAL counter of dosing volume - calculatedfrom OPERATING-kg-DIAGRAM for therespective dosing pipe - is set

• Start of calculation of ACTUAL counter value for the dosed volume

• Measuring of furnace pressure P-DC/TS

• Measuring of rising time of melt to DC = t2

• PRESSURE RISE to FEED PRESSURE (P-FD):

• with PRESSURE RAMP AFTER DC (R-after DC)- see set value in LOG K17 = dosing pipe 1 or K18 = dosing pipe 2

OFFLINE: 7.65kgDOS. PIPE: ∅ 80/24mm

MANUALSCAN=CELL

DOSING... ON


t6 t7

t2 t3 t4 t5

DCTS=

DCM-DIE


INFO MODIFYDATA

DOSING by HAND


MANUALSCAN=CELL

DOSING... RUN

t6 t7

t2 t3 t4 t5

DCTS=

DCM-DIE

p= 99.37 mb nc= 6379 ac=

INFO MODIFYDATA

DOSING by HAND


33/288

WESTOMAT ProDos DPC

OPERATING MANUAL


DOSING


• A = PRESSURE START

• DC = DOSING CONTACT

• B = FEED PRESSURE REACHED

• C = ACTUAL counter = NOMINAL counter

• D = DC VERIFICATION (I-01 = 0)

• E = END DOSING CYCLE

• F = TOP-STOP reached

• FEED PRESSURE (P-FD) REACHED:

• P-FD - for value see LOG K06

• Start with dosing volume calculated from

OPERATING-kg-DIAGRAM

• ACTUAL counter = NOMINAL counter (AC = NC):

• Deaeration (reduction of furnace chamber pressure) to pressure level P -DEAE

• Start of time t-DEAE

• Start of DC verification time after deaeration (t5-DC)

• Start of t5 = lag time - for value see kg-DOS:NEW or MODIFY DATA

• t5 = LAG TIME COMPLETED:

• DC verification after t5-DC negative - dosingcycle END

• Rise to TOP -STOP holding pressure = **.*mbar below P-DC - for value see LOG K06

• TOP-STOP holding pressure (P-TS) reached.

t2 t3 t4 t5

sec

mbar

-DC/TSP

-TSP

-DEAEP

-DC/TSR

- after DCR

-FDP

-DEAEt

NC= NOM. COUNTER

AC = ACT. COUNTER

-TSP

A

DC

B C

F

E

t5-DC

D

-ADJt

∆P(TOP-STOP)


34/288



OPERATING MANUAL


DOSING PROCESS in WESTOMAT®

• without TOP-STOP

t2 t3 t4

mbar

-DCP

-DCR

- after DCR

-FDP

-DEAEt

secNC = NOM. COUNTER

AC = ACT. COUNTER

t5

0.0 mbar

A

DC

B C

t5-DC

D

E

The dosing process in the furnace consists of thefollowing steps:

• PRESSURE START to DOSING CONTACT (DC):

• Pressure ram R-DC - for value see LOG K08

• DOSING CONTACT (DC) with:

• NOMINAL counter (with partial correction) of dosing volume - calculated from OPERATING-kg-DIAGRAM for the respective dosing pipe - isset

• A = PRESSURE START

• DC = DOSING CONTACT

• B = FEED PRESSURE REACHED

• C = ACTUAL counter = NOMINAL counter

• D = DC VERIFICATION (I-01 = 0)

• E = END DOSING CYCLE


35/288

WESTOMAT ProDos DPC

OPERATING MANUAL


DOSING


• Start of calculation of ACTUAL counter value for the dosed volume

• Measuring of furnace pressure P-DC

• Measuring of rising time of melt to DC = t2

• PRESSURE RISE to FEED PRESSURE (P-FD):

• with PRESSURE RAMP AFTER DC (R-after DC)- for value see LOG K17 = dosing pipe 1 or K18= dosing pipe 2

• FEED PRESSURE (P-FD) REACHED:

• P-FD - for value see LOG K06

• Start with dosing volume calculated fromOPERATING-kg-DIAGRAM

• ACTUAL counter = NOMINAL counter

• Deaeration - pressure release from furnacechamber

• Start of time t-DEAE

• Start of DC verification time after deaeration (t5-DC)

• Start of t5 = lag time - for value see kg-DOS:NEW or MODIFY DATA

• t5 = LAG TIME COMPLETED:

• DC verification after t5-DC negative - dosingcycle END


36/288



OPERATING MANUAL


blank page


37/288

WESTOMAT ProDos DPC

OPERATING MANUAL

OPERATIONAL FUNCTIONSDOSING


DOSING VOLUME (DATA SHEET) 02.01.1

OFFLINE: kg-DOS-NEW DOS. PIPE ∅∅∅∅65/21mm

21.07.9913:34:57

HEATINGSCAN=CELL

↑ ↓, INPUT, ENTER, MEMO / ESC=back


5.75 kg = dosing volume (OFFLINE)+0.30 kg = AUTO-increase up to 0.75-0.25 kg = AUTO-decrease up to 0.75-28.0 % = furnace chamber-CORRECTION


INFO

In the kg-DIAGRAM set-up mode (see chapter 07.05)

of the ProDos ® DPC, the user-specific dosing range(from smallest to largest dosing volume in kg) isentered and saved.

For DOSING, the required dosing volume is entered asa kg value in the kg-DOS file and saved. The dosingvolume can be adjusted at a later stage, if required,see chapter 02.01.2.

A kg-DOS file contains the fol lowing parameters:

• 5.75 kg .................................. Dosing volume • + 0.30 kg .................................. AUTO-increase • 0.25 kg .................................... AUTO-reduction

• 28.0 % ................ Furn. chamb.-CORRECTION

- 32.0 % .................. .. Counter-CORRECTION,not displayed in this menu

• 1.7 s .......................................... Lag time • P-FD = 60 mbar ............................. Feed pressure • t4 = 0.75 s .......................................... Feed time

• DOSING VOLUME

• Die-specific dosing quantity in kg (max. 2decimals):

• the kg value must be entered in the menu for kg-DOS: NEW and MODIFY DATA.

• The display shows the operator-specificdosing volume range as a guideline for thekg values

• The feed volume can deviate by approx.

5% from the nominal value. • AUTO-INCREASE

• Die-specific quantity in kg (max. 2 decimals) of dosing volume increase:

• The dosing volume increase is used for dies

with additional inlets during dosing

processes where these inlets are not used • The dosing volume increase is activated

automatically via the DCM interface


38/288


DOSING VOLUME (DATA SHEET)

WESTOMAT ProDos DPC

OPERATING MANUAL


• AUTO-INCREASE (cont.)

• the kg value must be entered in the menu for

kg-DOS: NEW and MODIFY DATA. • There is a limit regarding the new value as it

is related to the nominal value of the kg-DOSING VOLUME.

• This restriction is indicated in the display as

a limit value.

• AUTO-REDUCTION

• Die-specific quantity in kg (max. 2 decimals) of dosing volume reduction:

• The dosing volume reduction is used in

dosing processes, that are carried outwithout DCM pressing process. It preventsthe increase of sprue.

• The dosing volume reduction is activated

automatically via the DCM interface

• the kg value must be entered in the menu for kg-DOS: NEW and MODIFY DATA.

• There are restrictions regarding the new

value as it is related to the nominal value of the kg-DOSING VOLUME.

• This restriction is indicated in the display as

a limit value.

• FURNACE-CHAMBER-CORRECTION

• %-value (1 to 99, without decimals) of thedosing volume correction, which compensatesfor the furnace-specific gradual reduction indosing volumes that occurs when the furnace isbeing emptied:

• the kg value must be entered in the menu for

kg-DOS: NEW and MODIFY DATA.

• The entry of an insufficient % value results ina continuous reduction in the dosing volumeas the furnace is being emptied

• The entry of a % value that is too highresults in a continuous increase in thedosing volume as the furnace is beingemptied

• There are restrictions regarding the new

value as it is related to the nominal % value.


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WESTOMAT ProDos DPC

OPERATING MANUAL



DOSING CONTROL 02011-A.doc Version: 12.99 A 3 - 4 02.01.1

• COUNTER-CORRECTION

• %-value (1 to 99, without decimals) of thedosing volume correction, which compensatesfor the system-specific gradual increase in thenumber of dosing processes that occurs whenthe furnace chamber pressure is being reduced:

• The counter correction is automaticallyactivated if the furnace chamber is not under pressure at the time of PRESSURE STARTfor dosing

• By activating this correction, the NOMINAL

counter of the dosing volume is reduced bythe equivalent of the entered value

• The % value is entered and modified in the

LOG set-up mode

• The entry of an insufficient % value results inan increase of the dosing volumes

• The entry of a % value that is too high

results in a reduction of the dosing volumes.

• LAG TIME

• Dosing process time in seconds with onedecimal; time from the start of the pressurereduction in the furnace chamber (END of metalfeed) until all melt has been poured into theshot sleeve:

• The sec value must be entered in the menu

for kg-DOS: NEW and MODIFY DATA. • There are restrictions regarding the new

value as it is related to the nominal secvalue.

• The entry of an insufficient sec value results

in the dripping of the melt onto the plunger

• The entry of a sec value that is too highresults in a prolonged total cycle time for thecast.

• FEED PRESSURE and FEED TIME

• The parameters for feed pressure (P-FD) andfeed time (t4) are automatically recalculated anddisplayed upon the entry of a kg value:

• The operator cannot directly enter the values

of these parameters.


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WESTOMAT ProDos DPC

OPERATING MANUAL


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WESTOMAT ProDos DPC

OPERATING MANUAL



DOSING VOLUME - NEW / CORRECTION 02.01.2


10.03.0013:34:57 HEATINGSCAN=CELL



P r o D o s




kg-DOS:NEW DOSING

F 1 F 2 F 3 F 4 F 5


10.03.0013:34:57 HEATING

SCAN=CELL

↑ ↓= PIPE SELECTION, ENTER / ESC=back

SELECTION DOSING PIPE

∅ 65 /21 mm NO 1 = DOSING PIPE

∅ 80 /24 mm NO 1 = DOSING PIPE

INFO


10.03.0013:34:57

HEATINGSCAN=CELL

↑ ↓= PIPE SELECTION, ENTER / ESC=back

SELECTION DOSING PIPE

∅∅∅∅ 65 /21 mm NO 1 = DOSING PIPE

∅ 80 /24 NO 1 = DOSING PIPE

INFO


10.03.0013:34:57

HEATINGSCAN=CELL



3.55 kg = dosing volume (OFFLINE)+0.00 kg = AUTO-increase up to 4.27

0.00 kg = AUTO-decrease up to 3.2528.0 % = furnace chamber-CORRECTION


INFO

At each change of tools, the die-speci fic dosingvolume and other parameters of the DOSING VOLUME

file must be entered:

• these modifications are made in the kg-DOS NEWmenu.

If the dosing volume or any of the parameters of thekg-DOS VOLUME file are altered, the respective datamust be modified: • these modifications are made in the menu

MODIFY DATA.

kg-DOS: NEW In BASIC STATUS or F5 STATUS, press

• multi-function key F 4 :

• The display changes to entry status or dosingpipe selection status:

• The dosing pipe selection status allows for

the selection of the respective dosing pipe. Itis only activated if two different dosing pipeshave been entered in the LOG.

• Press

• or to place cursor in dosingpipe line

and press key

• The display changes to kg-DOS entry status:NEW, and the following values are displayed(see also chapter 02.01.1): - Dosing volume range

- The previously entered dosing volume andthe NEW dosing volume must be entered

- The values for AUTO-INCREASE andREDUCTION are reset to 0.0 and must bere-entered, if necessary

- The previously entered value of the furnacechamber CORRECTION must betransferred

- The previously entered T5 lag time – mustbe transferred

- The values for P-FD and t4 correspond tothe previously entered dosing volume andare recalculated for the NEW entry.


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DOSING VOLUME – NEW / CORRECTION

WESTOMAT ProDos DPC

OPERATING MANUAL


• EXAMPLE OF ENTRY (kg-DOS: NEW)

• 5.7 kg is the NEW, die-specific dosing volumeto be entered:

5 . 7 and continue

- The values for P-FD = 60 mbar and t4 = 1.29

sec are recalculated and automaticallydisplayed

ATTENTION

Entered values that are not within the dosingvalue range (here between 2.5 and 7.35) arerejected as TOO HIGH / TOO SMALL.

• As in this example, the new die is to be usedwithout inserts, and entry for AUTO-INCREASE

is not necessary:

- Continue with

• The tool to remove cast from die grasps the castat the sprue. Excessive sprues may result indisturbances; the pressing processes aresignalled to the unit via DCM interface.

- Enter 0.3 kg (recommended value) for AUTO-

REDUCTION

0 . 3 and continue

ATTENTION

The max. value for REDUCTION is displayed(here – 0.57 kg) Values that exceed this limitare rejected as TOO HIGH.

• The set value for the furnace chamber-CORRECTION (28%) is based on many years of experience. It ensures that the dosing volumeremains constant while the furnace is graduallyemptied. This value should not be altered.

- Continue with

• The existing value for t5-LAG TIME (1.7 sec) is

based on many years of experience. As thedosing channel length and inclination have notbeen changed in this example, the values mustnot be altered.

- Continue with

ATTENTION

For the furnace chamber-CORRECTION and thet5 LAG TIME, enter real numbers (not 0). Higher values are rejected as TOO HIGH.

OFFLINE: kg-DOS-NEW DOS. PIPE:∅∅∅∅65/21mm

10.03.00 13:34:57

HEATING SCAN=CELL



5.70 kg = dosing volume (OFFLINE)

+0.00 kg = AUTO-increase up to 0.57

-0.30 kg = AUTO-decrease up to 0.57

28.0 % = furnace chamber-CORRECTION

1.7 s = t5 - lag time

P-FD = 60 mbar / t4 = 1.29 s

INFO


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WESTOMAT ProDos DPC

OPERATING MANUAL




OFFLINE: kg-DOS-NEW DOS. PIPE:∅∅∅∅65/21mm

10.03.00 13:34:57

HEATING SCAN=CELL

ATTENTION: DATA HAVE BEEN MODIFIED!

F1 - SAVE DATA MODIFICATION F3 – DO NOT SAVE DATA MODIFICATION KEEP DATA UNMODIFIED F5 - BACK TO ENTRY

MEMO = YES

MEMO =

NO

BACK TO

ENTRY

F 1 F 2 F 3 F 4 F 5

OFFLINE: 5.60kg DOS. PIPE: ∅ 65/21mm

10.03.00 13:34:57

HEATING SCAN=CELL

EXT-KEY DOS-ON /instruction/ ESC=back To DOSING by HAND:

DCM-DIE = READY FOR DOSING! INFO

MODIFYDATA

kg-DOS:

NEW

DOSING

F 1 F 2 F 3 F 4 F 5

OFFLINE: 5.60kg

DOS. PIPE: ∅ 65/21mm

AUTO

SCAN=CELL

DOSING

... ON

t2 t3 t4 t5t1

t9 DC

DCM-DIE

t6 t7 t8

TS=

WESTOMAT: AVAILABLE = 890 kg MELT INFO

MODIFYDATA

DOSING

F

1

F

2

F

3

F

4

F

5

After entry and pressing of key

the LED of the MEMO key is blinking (ready to

save): • Save entered data:

• press MEMO key; the display

changes to saving mode; continue with

• F 1 MEMORY = YES:

The new values are saved

• F 3 MEMORY = NO:

The new values are deleted and the previousvalues remain saved; the display returns toinitial status

• F 5 BACK TO ENTRY:

The previous values are not overwritten; thedisplay returns to the entry form, where thenewly entered values are displayed;additional entries and modifications can bemade.

The entry of a NEW kg-DOS-VOLUME file iscompleted.

MODIFY DATA To modify a parameter of an existing kg-DOS VOLUMEfile, proceed as follows:

• in F5 STATUS, use multi-

function key F 3 = MODIFY DATA or

• In DOSING STATUS, press

multi-function key F 3 = MODIFY DATA or


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WESTOMAT ProDos DPC

OPERATING MANUAL


• EXAMPLE OF ENTRY (MODIFY DATA)

The dosing results are too small by approx. 0.3 kgand are further gradually reduced by 0.2 kg as the

furnace is being emptied. The existing kg-DOS VOLUME file must beadjusted: - Dosing volume - from 5.6 to 5.9 kg - Furnace chamber-CORRECTION - from 28 to33%

The control is in AUTO-DOS mode and theMODIFY DATA status has been activated.

• Enter NEW dosing volume: 5.9 kg

5 . 9 and continue

- The values for P-FD = 60 mbar and t4 = 1.49sec are recalculated and automaticallydisplayed.

ATTENTION

Entered values that are not within the dosingvalue range (here between 4.53 and 6.67) arerejected as TOO HIGH / TOO SMALL.

• In this example, the die is to be used withoutinserts and an entry for AUTO-INCREASE is notnecessary:

- Continue with

• AUTO-REDUCTION is carried out correctly – amodification is not necessary:

- Continue with

• Due to the dosing volume reduction that resultsfrom the furnace being gradually emptied, the %value of the furnace chamber-CORRECTIONmust be increased accordingly:

- Enter 33 % (recommended value)

3 3 and continue

• The value for t5-LAG TIME (1.7 sec) is based onmany years of experience and must not bemodified.

- Continue with

ATTENTION

For the furnace chamber-CORRECTION and thet5-LAG TIME, enter real numbers (not 0).Correction is only possible up to a certainextent. Values that exceed this limit are rejected

as TOO HIGH.


AUTO SCAN=CELL

DOSING ... ON

↑ ↓, INPUT, ENTER and MEMO / ESC=back kg-DOS-RANGE: 4.53 to 6.67 kg

5.60 kg = dosing volume (OFFLINE) +0.00 kg = AUTO-increase up to 0.56 -0.30 kg = AUTO-decrease up to 0.56 28.0 % = furnace chamber-CORRECTION 1.7 s = t5 - lag time P-FD = 60 mbar / t4 = 1.32 s

INFO


5.90 kg = dosing volume (OFFLINE)

+0.00 kg = AUTO-increase up to 0.56

-0.30 kg = AUTO-decrease up to 0.56

33.0 % = furnace chamber-CORRECTION

1.7 s = t5 - lag time

P-FD = 60 mbar / t4 = 1.49 s


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WESTOMAT ProDos DPC

OPERATING MANUAL





AUTO SCAN=CELL

DOSING ... ON

ATTENTION: DATA HAVE BEEN MODIFIED! F1 - SAVE DATA MODIFICATION F3 – DO NOT SAVE DATA MODIFICATION KEEP DATA UNMODIFIED F5 - BACK TO ENTRY

MEMO = YES

MEMO =

NO

BACK TO

ENTRY

F 1 F 2 F 3 F 4 F 5

OFFLINE: 5.90kg DOS. PIPE ∅ 65/21mm

AUTO SCAN=CELL

DOSING ... ON

t2 t3 t4 t5t1

t9 DC

DCM-DIEt6 t7 t8

TS=

WESTOMAT: AVAILABLE = 890 kg MELT INFO

MODIFYDATA

DOSING

After entry and pressing of key

the LED of the MEMO key is blinking (ready to

save): • Save entered data:

• press MEMO key; the display

changes to saving mode; continue with

• F 1 MEMORY = YES:

The new values are saved

• F 3 MEMORY = NO:

The new values are deleted and the previousvalues remain saved; the display returns toinitial status

• F 5 BACK TO ENTRY:

The previous values are not overwritten; thedisplay returns to the entry form, where thenewly entered values are displayed;additional entries and modifications can bemade.

ATTENTION

The above data can be corrected at any time bymeans of MODIFY DATA without interruption of the dosing process.

The data is saved as usual, but apply only to thenext dosing cycle.

The entry of a NEW kg-DOS-VOLUME file is nowcompleted.


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OPERATING MANUAL


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WESTOMAT ProDos DPCOPERATING MANUAL


DOSING CONTROL 0202-A.doc Version: 12.99 A 1 / 12

INTERFACE: WESTOMAT - DCM 02.02

The controls of the die-casting machine (DCM) and theWESTOMAT with the ProDos DPC are connectedvia an interface. This interface is designed accordingto the highest safety standards of the die-castingindustry and coordinates all processes.

The signal interface processes the following signals:

• From DCM to WESTOMAT = input signals to the

ProDos DPC:

• auto-fill test (optional) ............................. I-17

• auto-operation ON .................................. I-18

• die closes .............................................. I-19

• die closed 1 ........................................... I-20

• die closed 2 (optional) ................. ........ . I-21• die ready for injection 1 .......................... I-22

• die ready for injection 2 (optional) ........... I-23

• plunger in back position .......................... I-24

• discontinue synchro. operation (optional).. I-25

• kg-reduction (optional) ........................... I-26

• kg-increase (optional) ............................. I-27

• From WESTOMAT to DCM = output signals of

ProDos DPC:

• metal supply in automatic ....................... O-09

• metal filling in (optional) ........................ O-10

• release for injection 1 ............................ O-11• Release for injection 2 (optional) ............ O-12

• disturbance metal supply ............... ........ O-13

• ready for dosing ON ............................. O-14

In addition to the above signals, the controls are alsointerconnected as regards the mandatoryEMERGENCY-STOP. The power supply part of the

WESTOMAT HEATING control is not connected tothe EMERGENCY STOP.

The switching status of the DCM signals correspondsto the logical machine processes. The interface

request by the ProDos DPC takes into consideration

these logical machine processes. In the event of discrepancies, dosing is halted, while a DCM positionerror warning is issued. Alternatively, the dosing isinterrupted and an DCM ERROR MESSAGE is issued.

A WESTOMAT dosing operation is only possible if the signal exchange with the DCM is properlyestablished.

The signals are designed as floating interrupters at asignal voltage of 24 V DC.

Certain die-casting machines are equipped withstandard optional functions that are integrated in theinterface signalling system. These signals are labelled

as op t i ona l in this description.


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INTERFACE: WESTOMAT - DCMWESTOMAT ProDos DPC

OPERATING MANUAL

02.02 2 / 12 0202-A.doc Version: 12.99 A DOSING CONTROL

CHARACTERISTICS OF INPUT SIGNALS

• AUTO-FILL TEST ....................................... I-17

This signal is used by certain die-casting machinesfor a fill test of the DCM die, i.e. for the testing of the dosing volume and switching thresholds of theend position of the plunger.

Requirements for the optional DCM function AUTOFILL TEST:

• Complete WESTOMAT control functions untilstatus MANUAL DOSING ... ON – continue toREADY FOR DOSING, O-14 = 1

• Close DCM die completely in status MANUAL

• By parallel switching of the signals I-17 and I-18 = from 0 to 1, a single AUTO DOSINGprocess is carried out. See flow diagram.


MANUALSCAN=CELL

DOSING... ON


t6 t7

t2 t3 t4 t5

DCTS=

DCM-DIE


INFO MODIFYDATA

MANUAL by HAND

• FLOW DIAGRAM: AUTO-FILL TEST

• from DCM toWESTOMAT:

I-19

I-18

I-20 + 21

I-22 + 23

I-24I-25

I-26

I-27

I-17

• Switching DOS-ON .................

• MANUAL DOSING ... END

• MANUAL DOSING ... ON ...

• DOSING CONTACT ................

• AUTO DOSING ... RUN .......

• from WESTOMATto DCM:

O-09

O-10

O-11 + 12

O-14

ATTENTION

After starting the ProDos DPC from BASICSTATUS to DOSING MODE, the switching status I-17 = 0 is checked and, if incorrect, position error I-17 = 1 is signalled.


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WESTOMAT ProDos DPC

OPERATING MANUAL


INTERFACE: WESTOMAT - DCM

DOSING CONTROL 0202-A.doc Version: 12.99 A 3 / 12 02.02


MANUALSCAN=CELL

DOSING... END

instruction / EXT.-KEY DOS-OFF

Instruction for AUTO-DOSING:- Set DCM into AUTO !

Instruction for MANUAL DOSING:- CLOSE DCM-DIE in position MANUAL!

completely !



AUTOSCAN=CELL

DOSING... ON

_ WESTOMAT: AVAILABLE = 890 kg MELTINFO MODIFY

DATA

• AUTO-OPERATION ON ............................... I-18

If the DCM is in -AUTO and AUTO mode, the signal

switches to I-18 = 1. The ProDos

DPC is switchedfrom MANUAL mode to AUTO-DOS mode.

The switching to AUTO must be started from MANUALmode of the DCM control:

• while DCM die is open

• Set ProDos DPC to DOSING mode (advanceand retract plunger once) and continue tooperate according to instructions AUTO-MANUAL

• Set DCM control to -AUTO or AUTO mode:

• The signal METAL FEED TO AUTO, O-09

switches from 0 to 1.

• FLOW DIAGRAM: Start AUTO-DOS

• from DCM toWESTOMAT:

I-19

I-18

I-20 + 21

I-22 + 23

I-24

I-25

I-26

I-27

I-17

• Switching DOS-ON .................

• MANUAL DOSING .. END..

• AUTO DOSING .. ON .........

• from WESTOMATto DCM:

O-09

O-10

O-11 + 12

O-14

ATTENTION


A switching to AUTO mode at an earlier stage is

not possible and the ProDos DPC issues positionerror I-18 = 1.

During dosing operation AUTO DOSING ... RUN,the switch position I-18 = 1 is monitored: if I-18 =from 1 to 0, dosing is interrupted and DCMDISTURBANCE is signalled.


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OPERATING MANUAL


• DIE CLOSES ....................................... I-19

This signal switches in MANUAL, -AUTO and

AUTO mode of the DCM. as fol lows: I -19 = from 0 to1, if the closing of the movable die plate is started.

In MANUAL DOSING mode, I-19 is only queried inthe process of the logical switching sequence of thesignalled closing movement of the DCM die.

In AUTO DOSING mode, the switching of I-19 =from 0 to 1 initiates the following:

• Measuring of closing time (t 6) of the DCM die

• in AUTO-SYNCHRON-DOS: initiation of synchronization time (t1).

ATTENTION


The signalling of the start of movement of the dieplate is important in order to maintain the repeatedaccuracy of the closing time (t 6) of below 0.25sec.

During dosing operation AUTO DOSING ... RUN,the switching position I-19 = 1 is monitored: if I-19= from 1 to 0 after PRESSURE START and if I-20 /21 = 0, dosing is interrupted and DCMDISTURBANCE is signalled.

• kg-INCREASE (OPTIONAL) ........................ I-27

This signal switches in MANUAL, -AUTO and AUTO mode of the DCM. The signal is used for dieswith additional inserts. I-27 = from 0 to 1, if thecommonly used inserts are not used in this cycle:

• If the “normal” dosing volume in used in such acase, the sprue is reduced accordingly.

The ProDos DPC automatically takes this increaseinto account, if I-27 = from 0 to 1 prior to the start of the die closing (I-19 to I-23 = 0).

ATTENTION

In addition to the function of dosing volumeINCREASE, I-27 = from 0 to 1 discontinues AUTO-synchronization for the next two process steps(similar to I-25).


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WESTOMAT ProDos DPC

OPERATING MANUAL




• DIE CLOSED 1 ............................................ I-20

• DIE CLOSED 2 (OPTIONAL) ......................... I-21..

The signals switch in MANUAL, -AUTO and AUTOmode of the DCM.I-20 and 21 = from 0 to 1, when thedie plates are adjacent during the closing movement,i.e. when the shot sleeve is closed at the front.´

For reasons of safety, the closing status of the DCMdie is signalled via two separate channels: hardwarewith software query, and hardware only.

In MANUAL DOSING mode, I-20 and I-21 are onlyqueried in the process of the logical switchingsequence of the signalled closing movement of theDCM die.

In AUTO DOSING mode, the switching of I-20 / 21 =

from 0 to 1 initiates the following:

• Measuring of closing time (t 6) of the DCM dieis completed (repeatable accuracy of this time isless than 0.25 sec):

• in AUTO-SYNCHRON operation (with DCM-DIE CLOSED) = release of metal feed toshot sleeve

• Measuring of closing time (t 7) of the DCM dieis started.

ATTENTION

After starting the ProDos DPC from BASIC

STATUS to DOSING MODE, the switching status I-20 / 21 = 0 is checked and, if incorrect, positionerror I-20 / 21 = 1 is signalled.

During dosing operation AUTO DOSING ... RUN,the switch position I-20 / 21 = 1 is monitored, andif:

• At DC = start of metal feed I-20 / 21 = 0, dosing isinterrupted and DISTURBANCE DC BEFOREDCM-DIE CLOSED is signalled.

• If, after PRESSURE START, I-20/21 = from 1 to 0and I-22 / 23 = 0, dosing is interrupted andDISTURBANCE DCM is signalled.


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OPERATING MANUAL


• DIE READY FOR INJECTION 1 ................... I-22

• DIE READY FOR INJECTION 2 (OPTIONAL) I-23

The signals switch in MANUAL, -AUTO and AUTOmode of the DCM. I-22 and 23 = from 0 to 1, if theclosing section of the DCM is locked at the closingmovement.

For reasons of safety, the closing status of theDCM die is signalled via two separate channels,e.g. hardware with software query, and hardwareonly.

In MANUAL DOSING mode, I-22 and I-23 arequeried prior to release.

In AUTO DOSING mode, the switching of I-22 / 23= from 1 to 1 initiates the following:

• Measuring of t 7 of the DCM closing time iscompleted. The repeatable accuracy of this timeis between 0.5 and 2.5 sec:

• In AUTO-ASYNCHRON = PRESSURESTART for dosing

• In AUTO-SYNCHRON (with DCM-DIECLOSED) = release for continued injection

• In AUTO-SYNCHRON operation (with DCM-DIE READY FOR INJECTION) = release of metal feed to shot sleeve

• Measuring of t 8, injection stop time (from DCMdie ready for injection to release) is started

• After DOSING END, RELEASE FORINJECTION 1 / 2 are only completed, if I-22 / I-23 = 1

ATTENTION

After starting the ProDos DPC from BASICSTATUS to DOSING MODE, the switching status I-22 / 23 = 0 is checked and, if incorrect, positionerror I-22 / 23 = 1 is signalled.

During dosing operations MANUAL and AUTODOSING … RUN, the switching positions I-22 / I-23= 1 are monitored: if I-22 / I-23 = from 1 to 0,

dosing is interrupted and DCM DISTURBANCE issignalled.


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WESTOMAT ProDos DPC

OPERATING MANUAL




• PLUNGER IN BACK POSITION ................... I-24

This signal switches in MANUAL, -AUTO and

AUTO mode of the DCM. I-24 = from 0 to 1, if theplunger has reached the back position.

In DOSING MODE and in F5 STATUS, the sw

dosing control

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