LIAD ColorSave 1000ST-INJ User manual

LIAD Weighing and Control Systems Ltd.
Sky Street, POB 10, Misgav Industrial Park, M.P. Misgav 2017400, Israel
Tel: [phone] Fax: [phone] Email: [email protected]o.il www.liad.co.il
ColorSave 1000ST-INJ
Single-component masterbatch/additive gravimetric
feeder for injection molding machines
User Manual
Edited: 01/17

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LIAD Weighing and Control Systems Ltd 2
TABLE OF CONTENTS
Equipment Handling And Safety ............................................................................................4
1.0 Introduction........................................................................................................................5
2.0 Product Overview ..............................................................................................................6
2.1 Feeding System .............................................................................................................6
2.2 Feeding (dosing) Screws ..............................................................................................8
2.3 Control Unit ....................................................................................................................9
2.3.1 ColorSave 1000ST-INJ Controller Front View ....................................................9
2.3.2 ColorSave 1000ST-INJ Controller Rear View .....................................................9
3.0 Installation........................................................................................................................10
3.1 General Safety Notes And Warnings ........................................................................10
3.2 Mechanical Installation ...............................................................................................11
3.2.1 Mounting To The Injection-Molding Machine Throat .....................................11
3.2.2 Releasing The Load Cell......................................................................................11
3.2.3 Venturi Loader Installation .................................................................................12
3.2.4 Control Unit Mounting .........................................................................................12
3.3 Electrical Installation...................................................................................................13
3.3.1 Connections...........................................................................................................13
3.3.2 Sensor Cable Wiring Options..............................................................................14
4.0 Operation..........................................................................................................................15
4.1 General..........................................................................................................................15
4.1.1 Operation Modes..................................................................................................15
4.1.2 MB/AD Feeding Modes ........................................................................................16
4.1.3. Speeds Displayed On Main Screen...................................................................16
4.1.4 Gram Per Rotation ...............................................................................................17
4.2 Starting Sequence .......................................................................................................18
4.2.1 Main Screen For Mode "0" (Gravimetric mode, with machine dosing time)
..........................................................................................................................................18
4.2.2 Main Screen For Mode "1" (Gravimetric mode, with constant dosing time)
..........................................................................................................................................18
4.2.2.1 Changing Screw Feeding Time In Mode "1".................................................19
4.2.3 Main Screen For Mode "2" (Volumetric mode, with machine dosing time) 19
4.2.3.1 Changing Screw Speed In Mode "2"..............................................................19
4.2.4 Main Screen For Mode "3" (Volumetric mode, with constant dosing time) 20
4.2.4.1 Changing Screw Speed And Feeding Time In Mode "3" ............................20
4.2.4.2 Changing Screw Revolutions And Speed In Micro Mode "3" .....................21
4.3 Configuration Parameters Setup ...............................................................................22
4.3.1 Setting Parameter Values ...................................................................................22
4.3.2 Setting Installed Screw Number ........................................................................22
4.3.3 Setting Desired Operation Mode........................................................................23
4.3.4 Setting Max/Min Hopper Weight Parameters ..................................................23
4.3.5 Setting Recipe Mode............................................................................................23
4.3.6 Setting Cavity Mode.............................................................................................24
4.3.7 Setting Permitted Tolerance...............................................................................24
4.3.8 Setting Alarm Output Type.................................................................................24
4.3.9 Gravimetric/Volumetric Switch...........................................................................25
4.4 Accumulated Data Display .........................................................................................26

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4.5 Failure Alarms ..............................................................................................................27
4.5.1 “No Material” Alarm .............................................................................................27
4.5.2 “Over/Under Speed (dose)” Alarms ..................................................................27
4.5.3 “Calibration Failure” Alarms................................................................................28
4.5.4 “Feed Deviation” Alarm .......................................................................................28
4.5.5 “No Rotation” Alarm ............................................................................................29
4.5.6 “Out Of Tolerance” Alarm ...................................................................................29
4.5.7 Alarm Output (J2) ................................................................................................29
4.5.8 Alarm List ..............................................................................................................29
4.5.9 Alarm Log ..............................................................................................................29
4.6 Working With Recipes.................................................................................................30
4.6.1 Modify Recipe .......................................................................................................30
4.6.2 Select Recipe ........................................................................................................31
4.7 Working With Cavities.................................................................................................31
4.7.1 Change Number Of Cavities ...............................................................................31
4.7.2 Setting Number Of Cavities In The Recipe ......................................................32
5. Maintenance .......................................................................................................................33
5.1 Password.......................................................................................................................33
5.2 Static Calibration..........................................................................................................33
5.3 Dynamic Calibration ....................................................................................................33
5.4 Emptying And Cleaning ..............................................................................................34
5.5 Replacing The Dosing Screw .....................................................................................34
5.6 Emptying / Refilling The Feeding Screw ..................................................................35
5.7 Moving Feeder To Another Injection Machine Or Replacing Controller..............35
5.8 Troubleshooting...........................................................................................................36
5.9 Control Parameters .....................................................................................................38
5.10 Communication Option.............................................................................................39
5.11 Trends .........................................................................................................................40
5.11.1 Trend Speed .......................................................................................................40
5.11.2 Trend Percentage ..............................................................................................40
6 Technical Data.....................................................................................................................41
6.1 Technical Features ......................................................................................................41
6.2 Environmental Conditions ..........................................................................................42
Appendix A: Load Cell Protection Device............................................................................43
Appendix B: Static Calibration..............................................................................................45
1. General............................................................................................................................45
2. Calibration Process ........................................................................................................45
Appendix C: Dynamic Calibration ........................................................................................48
1. General............................................................................................................................48
2. Calibration Process ........................................................................................................48
Appendix D: Electrical Drawings ..........................................................................................50
Appendix E: EC-Declaration Of Conformity........................................................................55

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LIAD Weighing and Control Systems Ltd 4
EQUIPMENT HANDLING AND SAFETY
Please read this first!
General
This manual has been written to enable operators to use the machine correctly. Always keep the
manual at hand and always follow the instructions.
The operator is completely responsible for the operating safety of the system, and therefore all
operators must have full knowledge of its proper use.
Any use in a manner not specified in the user manual or any attempt by the user or non-authorized
personnel to disassemble or modify the machine shall render the warranty invalid and the
manufacturer shall not be responsible for any damage to persons or property.
The equipment must be installed, operated, and maintained only by skilled personnel who have
read and understood this manual.
LIAD is not responsible in any way for the quality of the products produced by the injection
machine on which LIAD equipment has been installed. Product quality is the sole responsibility of
the customer.
All technical data contained in this manual are the exclusive property of LIAD Weighing and
Control Systems Ltd. and must be considered as confidential. Therefore no reproduction or
publication of this manual, or any part thereof, is allowed without written authorization by the
manufacturer. Moreover, this manual shall not be used for purposes other than those connected to
installation, use and maintenance of this equipment.
Safety
▪Unqualified persons should not be allowed to handle this equipment.
▪Non-compliance with the installation and operation instructions may result in severe personal
injury or substantial property damage.
▪In order to avoid electric shocks, make sure that you first make all necessary connections,
before connecting the equipment to the mains. Also, make sure that it is protected by
effective short-circuit and over-voltage devices, and any other means required to protect the
operator, and that there is an effective earth (ground) connection to the device.
▪Only qualified persons should perform any installation, maintenance, and repair work, and
only when the system is fully disconnected from the power supply mains. For the ensured
safety of you and your colleagues:
oObserve all instructions for operation and maintenance of this equipment
oPay attention to all warning signs!
oLearn the equipment's safety devices and make sure they are in working order before and
after every operation
oDo not operate the equipment if the safety devices are not operating correctly
Please contact your LIAD representative if you have any questions about the safety of this system.

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1.0 INTRODUCTION
ColorSave 1000ST-INJ is a single-component, gravimetric masterbatch/additive feeder for injection
molding machines.
During normal operation, the device controls the weight of the masterbatch/additive (from now on
referred to as MB/AD)fed into the machine with each injection shot, using a loss-in-weight method.
By continuously measuring the weight of the material in its hopper, the system immediately detects
any deviation from the preset MB/AD weight, and automatically corrects this by regulating the current
(rpm) of the feeding screw.
If required, the feeder can operate in “constant” (non-regulated) current mode - the motor works at a
pre-selected current (rpm) without being regulated by the controller.
The MB/AD is fed directly into the injection machine’s feeding throat through a neckpiece adapter.
The ColorSave 1000ST-INJ is fitted with a feeding screw; there are 5 standard types of screw for
varying dosing ranges. Note that correct selection of the screw is instrumental in obtaining very high
accuracy.
The feeder can be equipped with an integral Venturi loader, which automatically refills the hopper
whenever its contents fall below a predefined minimum weight.
The feeder’s entire operation is automatically controlled by a powerful, sophisticated, yet easy-to-
operate control unit.

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LIAD Weighing and Control Systems Ltd 6
2.0 PRODUCT OVERVIEW
2.1 Feeding System
Fig. 1: General View and Dimensions

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Fig. 2: Mechanical Details
1) Main bulk hopper
2) Neckpiece top flange
3) Neckpiece
4) Bridge
5) Sight glass
6) Neckpiece bottom flange
7) Injection machine throat
8) Adding flange
9) Feeding screw
10) Emptying aperture
11) Screw fixating clip
12) Support flange
13) STEP motor
14) Load cell protection device
15) Load cell
16) MB/AD hopper
17) Quick release latch
18) MB/AD loading inlet
19) Flexible loading pipe
20) Venturi suction tube
21) Pneumatic air inlet
22) MB/AD container

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2.2 Feeding (dosing) Screws
Choosing the right feeding screw is essential for achieving the required dosing accuracy. The
following table shows the screws available and their material dosing capacities:
Feeding Screw
Capacity
0
Micro-capacity
1-3 pellets/shot
1.1
Low-capacity- standard
0.1 –4 Kg/hr
1
Low-capacity –smooth*
0.1 –4 Kg/hr
2
Medium-capacity
0.2 –10 Kg/hr
3
High -capacity
0.4 –18 Kg/hr
4A
Extra-capacity (3/4")
0.6 –35 Kg/hr
* for particular materials –consult with your LIAD representative
Notes:
a) Indicated screw capacity values are typical for free flowing granular 0.7 Kg/L bulk density
materials. Actual capacity depends on actual material features such as bulk density, flow ability,
pellet size etc., and also on the hopper volume.
b) The identification number is marked on each screw (micro screw is marked with "C").
c) Please consult with LIAD regarding higher capacity screws.

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J4: Communication port
2.3 Control Unit
2.3.1 ColorSave 1000ST-INJ Controller Front View
Fig. 3: ColorSave 1000ST-INJ
controller front view
2.3.2 ColorSave 1000ST-INJ Controller Rear View
Fig. 4: ColorSave 1000ST-INJ controller rear view
Gravimetric/volumetric
switch
J1: Load cell input
J2: Alarm output
J5: STEP motor control output
J3: Sensor input
S1: On/Off power inlet
P1: Pneumatic valve

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3.0 INSTALLATION
3.1 General Safety Notes And Warnings
This manual contains information required for installation.
Adherence to the safety notes is mandatory. Non-compliance will invalidate your warranty.
When you receive the equipment, you should immediately check whether any damage occurred
during transport. If this is the case, please consult your agent before installation.
Warning
Persons who are not qualified should not be allowed to handle this equipment/system. Non-
compliance with the installation and operation instructions can result in severe personal injury or
substantial property damage. Only qualified personnel should be allowed to work on this
equipment/system.
In order to avoid electric shock, make sure that you first make all necessary connections, before
connecting the equipment to the mains. Also, make sure that it is protected by effective short-circuit
and over-voltage devices, and any other means required to protect the operator, and that there is an
effective earth (ground) connection to the device.
Caution: The motor has a permanent magnetic field. Never exceed Imax (6A).
Any installation, maintenance and repair intervention must be performed only by skilled personnel,
and only when the equipment/system is disconnected from the power supply mains.