Translation of the original instructions
Gear metering system
Contents
1
General
2
Safety rules
3
Structure and function
4
Comissioning
5
Operation
6
Maintenance
7
Disposal
8
Conformity and protocols
9
Parts lists
10
Circuit diagrams
11
Accompanying
12
documentation
© Hilger u. Kern GmbH, Käfertalerstr. 253, 68167 Mannheim, Germany
Phone: +49 621 3705-500, E-mail: info@dopag.de, Web: www.dopag.de
4/2022
Material data
13
Customer documentation
14
Key Word Index
15
2/
eldo100-029/0000000343-001-EN
1
2
Contents
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
3
Object of Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keeping the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note on changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Margin column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mandatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazardous zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Particular sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Danger from electric power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Danger from toxic and combustible materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4 Danger from high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.5 Danger due to chemical reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.6 Risks caused by machine malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.7 Beware of harmful vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Responsibilities of the operating company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Changes on the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Flushing and cleaning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Safety information for material vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Warranty and liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.2
3.3
4
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....8
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Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1
4.2
Basic function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Compressed-air maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Material vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Vessel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5 Material filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.6 Level probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.7 Metering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.8 Volume counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.9 Recirculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.10 De-aeration valve with blocking attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eldo100-029/0000000343-001-EN
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1/3
4.3
4.4
4.5
4.6
5
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1
5.2
4/1
4.2.11 Static discharge system ID 2/2 and ID 4/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.12 Plastic mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.13 Sealing cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.14 Diaphragm vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.15 Start trigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.1 Display/navigation information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2 Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.3 Main menu (start screen). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.4 Component-specific functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.3.7 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.8 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.9 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.10 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.11 Log-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Selectable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.1 Continuous metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.2 Shotwise metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.3 Programmed metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.4 Pre-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.5 Mixing ratio inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.6 Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.7 Discharge pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4.8 Automatic mixing ratio adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4.9 Interpolating flow rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4.10 De-aeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4.11 Stirring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Checks carried out automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.1 Pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.2 Potlife check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.3 Metering quantity monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.4 Mixing ratio inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.5 Filling level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.6 Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.7 Leakage check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.8 Operating data recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.1 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.2 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.3 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6.4 Gear metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6.5 MR40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operating location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
eldo100-029/0000000343-001-EN
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
6
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Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
7
Removing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising/Relocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2 Compressed-air connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum pump exhaust air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the level probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling (material vessel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
De-aerating the gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
De-aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flush the de-aeration valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the opening stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the gear metering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the volume counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the mixing ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting the mixing ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing setpoint values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activate the operating data recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refilling the material vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Request material consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving pressure from discharge system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset of agitator motor starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 77
. . . 78
. . . 80
. . . 80
. . . 81
. . . 84
. . . 84
. . . 85
. . . 85
. . . 87
. . . 93
. . . 95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.1
7.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Maintenance contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 DOPAG spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4 Operating materials and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.5 Adjustable seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance of the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eldo100-029/0000000343-001-EN
. . . 97
. . . 97
. . . 97
. . . 97
. . . 98
. . . 99
. . 100
1/5
7.3
7.4
7.5
7.6
7.7
7.8
8
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.1
8.2
9
7.2.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2.2 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.2.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.2.4 Material lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.2.5 Compressed-air maintenance unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.2.6 Silica gel air dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.2.7 Checking the material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.2.8 Material filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.2.9 Gear metering pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.2.10 Discharge system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.2.11 Diaphragm vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.2.12 Liquid separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.2.13 Touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Calibrate touch-screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Software information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Metering control unit software change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Data storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Buffer battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Disposing of the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Final system decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Conformity and protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.1
EC Declaration of Conformity (as per directive 2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10
Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
11
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12
Accompanying documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
13
Material data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
14
Customer documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
15
Key Word Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6/1
eldo100-029/0000000343-001-EN
General
2
General
2.1
Object of Operating Instructions
These operating instructions are to ensure the safe, intended and efficient use of the
equipment. They contain the relevant information for the safety, construction, function, commissioning, operating, servicing and disposal. The required information
can be located in the operating instructions using the contents index, the key word
index, title and marginal columns.
Ignoring the operating instructions and the safety information can lead to dangers
and restrictions for:
•
•
•
life and limb of the operator;
the system and material assets of the operating company;
efficient operation of the system.
NOTICE
Ignoring the operating instructions
The company DOPAG (hereafter called the manufacturer of the equipment) takes
no responsibility for any damage resulting from not observing the operating instructions.
► Observe the operating instructions!
2.2
Keeping the Operating Instructions
The operating instructions are regarded as a part of the machine. They must be
made available to personnel at all times. The machine operator must ensure that
both the operating and service personnel have read and understood them.
The operating instructions can be viewed on the touch screen. They are located in the
2.3
menu.
Target audience
Operators
Service personnel
The machine operator has the responsibility for ensuring that the operating and service staff have the appropriate qualifications. He must ensure that only company authorized personnel operate the machine.
Persons working at and operating the system must possess sufficient training for the
operations concerned. It is essential for personnel to have read and understood the
operating instructions.
Persons who service and repair the system must be skilled and:
•
•
•
adequately trained to undertake the operations necessary.
be familiar with and follow the relevant technical regulations and safety instructions.
have read and understood the operating instructions.
Skilled persons mean those whose training and experience have provided them with
adequate knowledge in the fields of hydraulics, pneumatics, material-handling technology and electrical engineering, and who are familiar with the regulations applica-
eldo100-029/0000000343-001-EN
2/7
General
ble to occupational safety and accident prevention, directives and generally
recognized rules on technology and standards, so that they can evaluate the operational safety of the system.
2.4
Note on changes
Text, illustrations and data conform to the technical status of the machine at the time
of these operating instructions going to print. The company reserves the right to
make changes in the interests of ongoing development.
2.5
Symbols and pictograms
The operating instructions contain various symbols and pictograms. They provide
warning signs, directions for action, information and indication signs to the operating
and maintenance staff.
D...
T...
Directions for action to be taken
 The triangle symbol indicates actions that must be carried out in a specific sequence.
• The dot symbol indicates the reaction to an action.
Help symbols regarding directions for actions to be taken
1
2
3
Help symbols are found in graphic diagrams only. They support a direction for action
to be taken by means of a sequence of numbers directly on the respective part. Help
symbols usually consist of a colored circle and a number.
Warning signs, prohibition signs and mandatory signs.
Notes on safety, instructions and warnings are indicated by the appropriate ISO
Safety Signs. They can be found in the operating instructions and on the machine
and it is essential that they are obeyed.
Pictograms
Buttons, switches, pressure gauges and functions are designated by pictograms in
the operating instructions and on the system itself. The letters A, B, C... in the pictograms identify the components.
Advice for the user
Notes for the users and tips for efficient operation of the system are indicated
by the light bulb symbol and typeset in bold type. Follow these instructions!
2.6
Margin column
The margin column contains additional information (pictograms, keywords and descriptions of illustrations). Such information points out hazards and makes it easier
to find what you search.
2.7
Cross-references
Cross references are typeset in italics. They reference information in other sections,
e.g. (14 Customer documents). These points can be found by means of te Contents
or the Key Word Index.
8/2
eldo100-029/0000000343-001-EN
General
2.8
Safety information
There are four types of safety information: Danger, warning, caution, note. They contain: Source of danger, consequences of the risk and avoidance measures to be taken.
Danger
Signal word to indicate a danger with a high risk that will lead directly to death or serious physical injury.
DANGER
Source of danger
Consequences of the risk
► Avoidance measures to be taken
Warning
Signal word to indicate a hazard with a medium risk that could possibly lead to death
or serious physical injury.
WARNING
Source of danger
Consequences of the risk
► Avoidance measures to be taken
Caution
Signal word to indicate a hazard with a low risk that can lead to minor or moderate
physical injury.
CAUTION
Source of danger
Consequences of the risk
► Avoidance measures to be taken
Note
Signal word for a possible damaging situation, were the system or anything in the
vicinity could be damaged.
NOTICE
Source of danger
Consequences of the risk
► Avoidance measures to be taken
eldo100-029/0000000343-001-EN
2/9
General
2.9
Prohibition signs
Caution
Prohibition signs forbid types of behavior that pose danger. Ignoring a prohibition
sign could lead to hazardous situations and most serious injuries.
Caution - fire, open flames and smoking are prohibited
This prohibition sign is used when there is a danger of fire due to flammable materials.
Caution - Warning of hand injuries due to movable parts
Danger of crushing fingers or hands due to movable parts of the system. Keep
hands away from the valve adjusting screw.
2.10
Warning signs
Warning
Warning signs warn of acute danger. Ignoring warnings can lead to a dangerous situation and most serious injuries.
Warning - General
This general warning sign is always used in conjunction with safety information. The
safety information must be observed without fail.
Warning - Caution: high voltage
Warning of a dangerous electrical voltage. If contact is made with components in this
danger area, serious injury possibly leading to death due to electric shock may occur.
Warning of rotating parts
Danger of serious hand injuries due to rotating parts. Keep hands away from the
danger area.
Warning of hand injuries
Danger of crushing limbs by parts of the system. Keep hands away from the lever
system and moving parts of the system.
Warning of overpressure
Behälter unter Druck!
Vessel under pressure!
Réservoire sous pression !
Serbatoio sotto pressione!
10/2
Risk of injuries due to squirting of materials hazardous to health. Discharge pressure
before opening the tank.
eldo100-029/0000000343-001-EN
General
2.11
Mandatory signs
Mandatory
Mandatory signs prescribe specific courses of action. They must be followed, as
they help protect against injury.
Wear protective gloves
Wearing protective gloves prevents contact with toxic substances. Caustic burns
and poisoning are avoided.
Wear protective goggles
Parts of the machine operate under pressure and spraying substances can cause
damage to eyes. Wearing eye protection avoids damage to eyes.
2.12
Labeling
The machine nameplate is located near the electrical control cabinet and provides
the following details:
1
Type designation
2
Machine number
3
Drawing number
4
Certificate
5
Year of construction
6
Voltage supply
7
1
Masch. Typ
Short-circuit breaking capacity
2
Masch. Nr.
8
Rated current
3
Zeichn. Nr.
9
Motor speed
4
Zertifikat
5
Bj.
10 Supply pressure
11 CE label
V~
12 Address of manufacturer
6
13 Performance
7
Max. Schaltverm. ISich.
8
I Nenn
9
n max
14 Voltage frequency
15 Phase shift angle
16 Protection class
17 Weight
10
/N/PE
kW
13
Hz
14
kA
A
min -1
bar
cosφ
15
IP
16
17
kg
11
12
eldo100-029/0000000343-001-EN
Hilger u. Kern GmbH
Käfertaler Straße 253
68167 Mannheim
info@dopag.com
www.dopag.com
+496213705-500
2/11
General
12/2
eldo100-029/0000000343-001-EN
Safety rules
3
Safety rules
3.1
Intended use
The equipment and its functions may only be used for the purposes of delivering,
metering and mixing. The prescribed environmental conditions for operation
(4.6.3 Ambient conditions) must be observed. Only those materials provided in the
chapter Material data may be used.
•
•
If the composition of the material changes, the use of the new material must be
clarified and approved by DOPAG Customer Service.
If a different type of material is to be used, this must be clarified and approved
by DOPAG Customer Service.
NOTICE
The use of material not approved by DOPAG Service can damage the equipment.
If for example seals cannot withstand the new composition, they will be destroyed.
► Information on your telephone contact can be obtained from www.dopag.com.
Explosive vapors
Mixing and metering materials that form explosive vapors is prohibited. This system
has no protection against explosion.
DANGER
Danger of explosion!
Operating the machine using materials that form explosive vapors can cause serious burns resulting from explosions.
► Do not mix or meter explosive materials.
Foodstuff
Mixing and metering foodstuffs is prohibited. This system has not been designed for
processing foodstuff. Toxic substances would contaminate foodstuff.
DANGER
Danger of poisoning!
The machine could be contaminated if operated with foodstuffs.
► Do not deliver nor meter foodstuffs.
3.2
Product safety
The system conforms to acknowledged rules of engineering and technology and the
relevant safety regulations. The correct operation of the equipment is required to
avoid damage and accidents. Operating it incorrectly or subjecting it to abuse may
imperil:
•
•
•
life and limb of the operator;
the system and material assets of the operating company;
efficient operation of the system.
The system may only be operated if it is in perfect condition and if the operating instructions are observed.
eldo100-029/0000000343-001-EN
3/13
Safety rules
3.3
Hazardous zones
The hazardous zone denotes the area on a system and/or in its vicinity in which
there are dangers to safety or personal health. There are various hazardous zones
around the system. All safety regulations given in the operating instructions and information signs on the system must be observed. Observe the safety regulations in
force for the respective installation site.
3.3.1
Particular sources of danger
Operating this machine is safe. However, hazards can arise in some situations. Adhere to the following points:
•
•
•
•
•
•
3.3.2
The oscillating pumps are powered by pneumatic or hydraulic cylinders. Never
reach into the area between the drive and the pump during operation. Otherwise
injury from crushing can result.
Only clean the drum pumps when they are de-pressurized. Never reach under
the follower plate at the scoop piston. When the pump starts, you could crush or
cut off your fingers.
Never reach into the opening of the gear pump coupling. Danger of serious hand
injuries due to rotating parts. Keep hands away from the danger area.
Under all situations when working on the equipment, whether installation, removal and re-installation, commissioning, operation, modification, adaptation,
maintenance and cleaning, the isolation procedure and safety information given
in the operating instructions must be observed.
All service and maintenance work on the machine must be only carried out after
switching off or de-pressurizing the machine.
In all cases observe local regulations applicable to safety and accident prevention.
Danger from electric power
Electricity is dangerous in many ways. Adhere to the following points:
•
•
•
•
•
•
3.3.3
Work on power supply systems may only be performed by qualified electricians.
Check the system's electrical equipment regularly. Loose connections and burnt
cables should be removed immediately or restored to their proper condition.
The control/switch cabinet must be kept closed at all times. Access is permitted
only to authorized staff with the key or tool intended for this purpose.
If work is necessary on live parts, a second person, who can turn off the main
switch in an emergency, must assist.
Otherwise, the main switch must be turned off and locked against unintended
switching on.
Remove the mains plug.
Danger from toxic and combustible materials
Depending on the material being processed, special rules and regulations regarding
occupational safety and accident prevention must be observed.
•
•
14/3
When using solvents or other corrosive chemicals, special precautions must be
taken, e.g. eye washing facilities.
During flushing and cleaning processes, vaporization of solvents may create an
explosive zone.
eldo100-029/0000000343-001-EN
Safety rules
3.3.4
Danger from high pressure
Pneumatic and hydraulic modules are pressurized. Adhere to the following points:
•
•
•
•
•
•
•
3.3.5
Only personnel with special knowledge and experience may work on hydraulic
systems.
When dealing with the system, you must wear protective goggles and gloves.
Depressurize any sections of the system to be opened and pressurized lines before starting the repair work.
Change hydraulic hose lines at appropriate intervals, even if no safety defects
are detected.
Pumps operate at high pressure. All pumps and lines must be relieved before
opening or assembly. No residual pressure may exist.
Otherwise, the main switch must be turned off and locked against unintended
switching on. The main switch (circuit breaker) isolates the entire system from
power supply. All electric functions are switched off and the discharge system
closes. Certain parts of the machine remain pressurized.
Remove the mains plug.
Danger due to chemical reactions
WARNING
Danger of burning! Fire hazard! Suffocation hazard!
After the media to be processed have been mixed, chemical reactions will take
place. These may result in the generation of heat, smoke, and fire.
► Do not mix excessive amounts of material! Mixed material should be fed into a
temperature-resistant container. There must be no inflammable material inside
the waste container.
3.3.6
Risks caused by machine malfunction
WARNING
Risks caused by machine malfunction
Machine malfunction can make material escape in an uncontrolled manner and
cause injury to eyes and skin.
► Wear eye protection and protective gloves.
3.3.7
Beware of harmful vapors
CAUTION
Beware of harmful vapors.
When working with open vessels or machine components at which material is discharged, harmful vapors can escape.
► Wear protective clothing and observe the material manufacturer's safety information.
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3/15
Safety rules
3.4
Responsibilities of the operating company
The following responsibilities are generally applicable to the company operating the
system:
•
•
•
•
•
•
•
•
3.5
Observe the generally recognized rules that apply to occupational safety. Moreover, observe the basic regulations and rules on occupational safety and accident prevention applicable on site.
The operating company is obliged to observe the regulations applicable to the
use of equipment, especially those specified in EC Directive 2009/104/EC.
The system may only be operated in a perfect and clean condition.
It is forbidden to remove, change, bypass or override any kind of protection,
safety or monitoring devices.
Redesigning or modifying this system is prohibited.
For repairs, please contact DOPAG Service www.dopag.com. Only genuine
DOPAG spare parts may be used.
Check the system at least once per shift for visible signs of damage and for correct functions.
The operating company is responsible for the safety regulations in dealing with
the material used.
Changes on the system
Changes on the system are basically prohibited. If changes become necessary,
please observe the following points:
•
•
•
•
3.6
Personal protective equipment
•
•
•
16/3
Do not undertake changes, add-on or modification to the system without express
approval by the manufacturer.
Do not undertake changes to system software without express approval by the
manufacturer.
All redesigning measures require written approval by the manufacturer.
Only genuine DOPAG spare parts may be used. Safe operation is not guaranteed if parts other than the genuine parts are used.
Wear eye protection and protective gloves.
For material-specific protective equipment, please refer to the safety data sheet
by the material manufacturer (see chapter 13 Material data).
The operating company must provide the required personal protective equipment.
eldo100-029/0000000343-001-EN
Safety rules
3.7
Flushing and cleaning the system
The material safety data sheets on the substances and materials used are an important factor when selecting flushing and cleaning agents.
NOTICE
There may be production residues or test material in the machine unless the
machine has been run in with original material.
During the initial use of the machine, such residues may result in defective products!
► During initial de-aeration, make sure to discharge sufficient material so that any
production residues or test material is flushed out thoroughly.
DANGER
Danger of explosion when using solvents!
When using solvents based on halogenated hydrocarbons, such as trichloroethane,
chemical reactions can be caused on aluminum and on galvanized parts. The parts
can oxidize and be destroyed as a result. In extreme cases, the reaction can occur
in an explosive manner.
► Do not use any solvents based on halogenated hydrocarbons.
When selecting flushing and cleaning agents, please observe the following points:
•
•
•
Observe the manufacturer's recommendations.
Machine components must be capable of withstanding the recommended solvents and cleaning agents. If you have any questions, please contact DOPAG
Service (www.dopag.com).
Observe the current material safety data sheets of your suppliers.
At certain points in these instructions, references are made to the replacement of
cleaning agents, oils and similar products. Material safety data sheets of the manufacturers of these materials are, as far as we are aware, quoted in these instructions
(see chapter Accompanying documentation). The current material safety data
sheets must be available and the instructions contained therein must be followed.
DANGER
Fire hazard!
When using cleaning agents containing solvents, an explosive atmosphere may be
created.
► It is forbidden to smoke or use fire near the machine area!
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3/17
Safety rules
3.8
Safety information for material vessels
•
•
•
•
•
3.9
These operating instructions contain only basic information on the use of material vessels. The dedicated operating instructions regarding the material vessels
must be read first (see chapter Accompanying documentation).
Do not undertake any changes on the material vessels, otherwise these could
impair safety. Do not manipulate the safety valves either. Operation of the material vessels is only permitted in unchanged original condition!
Any work on the material vessels may only be carried out when the material
pressure vessels are de-pressurized.
Before opening the material vessels, switch off the agitator and secure it against
being unintentionally switched on again.
If a safety valve activates in your system, replace it without delay. Otherwise, the
function of this safety system is not ensured.
Conformity
The equipment complies with the directives listed in the declaration of conformity
(9 Conformity and protocols).
3.10
Warranty and liability
In principle, our general conditions of sale and supply are applicable. They will be
available to the operating company no later than the date on which the contract is
concluded. Claims under the warranty and liability for personal and material damage
are excluded if they are due to one or several of the following causes:
•
•
•
•
•
•
•
•
•
•
•
•
18/3
Improper use of the machine.
Improper assembly, commissioning, operation and maintenance.
Operating the machine with defective or faulty safety systems or safety and protective devices not correctly attached or non-functional.
Disregarding instructions on safety, transport, storage, assembly, commissioning, decommissioning, maintenance, dismantling and disposal of the machine.
Unauthorized structural modification to the machine.
Unauthorized intervention to the system software.
Unauthorized changing of drive-power levels (power, rotational speed, etc).
Poor monitoring of machine parts subject to wear.
Repair work carried out improperly.
Disasters caused by extraneous influences and force majeure.
Use of spare parts which are not genuine DOPAG parts.
Damage arising from normal wear and tear.
eldo100-029/0000000343-001-EN
Structure and function
4
Structure and function
4.1
Basic function
The eldomix is a delivering, metering and mixing system using gear pumps. It is
used for processing low to medium-viscosity polyurethane-based multi-component
media.
It is designed to be eco-friendly and works without solvents. The components are
fed separately until they enter the mixer. Therefore, flushing of machine parts is not
required.
1
A component
2
B component
3
Material vessel
4
Agitator
5
Gear pump
6
Volume counter
7
Pressure monitoring
8
Discharge system
9
Plastic mixer
1
2
M
M
M
M
3
4
5
6
7
8
9
The media are located in the material vessels and will be fed to the gear pumps by
means of the vessel pressure. An agitator in the vessel containing the A component
homogenizes the material.
The gear metering pumps deliver the material to the discharge system, where it is
mixed in the mixer before being discharged. The A component can be delivered
back to the material vessel via the gear metering pump in the circuit.
The mixing ratio is calculated and controlled based on the test quantity.
Operation and data input is carried out on the touch screen. The control unit facilitates integration into partially or fully automatic production or assembly processes.
eldo100-029/0000000343-001-EN
4/19
Structure and function
4.2
Structure
1
Control unit
2
Vacuum pump for component A
3
A component metering
4
B component metering
5
Discharge system
6
A component material
vessel
7
B component material
vessel
8
Compressed-air maintenance unit
9
Vacuum pump for component B
6
7
1
10 Foot switch
8
2
3
9
4
5
10
4.2.1
Control unit
The control cabinet contains the electric components for controlling the machine.
1
Main switch
2
Indicator light with horn
3
Program selector switch
(optional)
4
Touch-screen
1
2
3
4
TOUCH
SIMATIC HMI
OFF
Vor Öffnen des Schaltschrankes
Hauptschalter ausschalten!
Avant d'ouvrir l'armoire de manoeuvre
declencher l'interrupteur principal!
Before opening of switch cabinet
put off main switch!
20/4
eldo100-029/0000000343-001-EN
Structure and function
4.2.1.1
Main switch
The main switch (circuit breaker) is used to turn the machine ON and OFF. It interrupts the power supply to the entire system. In this way, all electrical functions are
turned OFF and the dispensing valve closes. Certain components of the machine remain pressurized.
4.2.1.2
Indicator light with horn
Collective alarms are displayed by the indicator light. Additionally, the horn sounds.
4.2.2
Compressed-air maintenance unit
The compressed air maintenance unit supplies the machine with compressed air to
create optimum operating conditions. The inflow of compressed air is filtered. A silica gel de-humidifier (option) removes moisture from the air. When closing the main
valve for compressed air, the machine is de-aerated.
1
Compressed-air connection
2
Main valve for compressed air
3
Main air pressure controller (optional)
4
Distributor
5
Pressure gauge
6
Filter with water separator
7
Drain plug
8
Fine filter with water separator (option)
9
Silica gel air dehumidifier
(optional)
1
5
eldo100-029/0000000343-001-EN
3
2
6
7
4
8
9
4/21
Structure and function
4.2.3
Material vessel
The material vessels contain the component materials. They are pressurized in order to supply the material to the metering unit. The vessels may be equipped with
additional functions (refilling, recirculation, evacuation, sight glass, heating, agitator,
level probe, etc.).
1
Agitator motor (optional)
2
Level probe (option)
3
Star-shaped handle
4
Vessel cover
5
Cover seal
6
Material vessel
7
Probe rod
8
Agitator blades
9
Vessel fitting
10 Recirculation return line
11 Heating collar (optional)
12 Shut-off valve on material
outlet
13 Material outlet
14 Material filter
1
9
2
3
10
4
5
6
11
7
12
8
13
14
22/4
eldo100-029/0000000343-001-EN
Structure and function
4.2.4
Vessel fitting
The vessel fitting supplies compressed air to the material vessel. Use the pressure
regulator to set the vessel pressure. The vessel is ventilated via the air outlet valve.
The air coupling enables the compressed-air hose to be connected or disconnected
as necessary.
For material vessel evacuation, the vessel fitting is disconnected from the vessel
coupling.
1
Safety valve
2
Pressure gauge for vessel
pressure
3
Air coupling
4
Air shut-off valve
5
Pressure regulator for
vessel pressure
6
Sound absorber
7
Air outlet valve
8
Vessel coupling (optional)
3
4
1
2
5
6
7
8
4.2.5
Material filter
Contaminants in the material will damage the valve seats or cause clogging and
leakage. Material filters prevent contaminants from entering the system.
1
Filter housing
2
Material inlet
3
Material outlet
4
Housing cover
5
De-aeration screw
5
4
3
eldo100-029/0000000343-001-EN
1
2
4/23
Structure and function
4.2.6
Level probe
The level probe monitors the level in the container. Based on the probe signals, the
control unit issues a warning when the lower level is reached indicating that the container will soon be empty, or starts or stops the refilling process.
Depending on the respective machine, the level can be shown on the control
unit display.
1
Operating mode (MODE)
2
Save (SET)
3
Setting key (UP/DOWN)
4
Level display
5
Maximum level calibration
6
Switching output
7
Analog output
8
Minimum level calibration
9
Electronics module
4
9
5
1
X
6
2
10
7
11
8
3
15 mm
10 Measuring range
11 Probe rod
4.2.7
Metering
The gear motor drives the gear metering pump, which delivers the material to the
discharge system.
The metering units have been precisely adjusted to the material to be delivered and
to the specific metering task. These special adjustments involve e.g.:
•
•
•
•
•
•
24/4
Gear metering pump (size, pump backlash, coating and sealing system)
Pump carrier (version depending on the sealing system of the gear metering
pump)
Connecting block (size)
Pressure sensors (pressure range)
Shut-off valve on pump outlet (included or not included)
Volume counters (size, backlash variant and bearings)
– Required for MR-Control or MR regulation.
eldo100-029/0000000343-001-EN
Structure and function
1
Gear motor
2
Pump carrier with coupling
3
Grease nipple
4
Gear metering pump
5
Connecting block
6
De-aeration valve
7
Material outlet
8
Volume counter
9
Speed sensor (option)
1
2
3
4 5 6
9 10 11
7
8
12
10 Sealing fluid outlet
11 Material inlet
12 Pressure sensor
4.2.8
Volume counter
Inside the volume counter, there is a fitted gear pair. The gears are driven by the material flow. During the rotation, each tooth is detected by a measuring unit. The measuring volume is determined in cm³/pulse according to the material quantity which
has been delivered per tool pitch.
Type and size of the volume counter have been especially designed for the specific
application.
1
Electronic system
2
Protective earth conductor terminal
3
Measuring unit
4
Screw
5
4-pin M12 port
6
Nameplate
6
1
5
2
3
4
eldo100-029/0000000343-001-EN
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Structure and function
4.2.9
Recirculation
The ball valve is used to open the circuit. It must always be closed for metering functions.
Manual recirculation
1
Material hose to material
vessel
2
Cut-off valve
4.2.10
1
2
De-aeration valve with blocking attachment
De-aeration valves with blocking attachment are used where materials sensitive to
air and humidity are processed. After the valve has been operated, the sealing area
must be flushed to prevent the material from hardening inside the valve. The blocking fluid is injected into the grease nipple using a grease gun with the valve closed
until it flows out through the outlet and flushes out the material.
1
Knurled-head screw
2
Grease nipple
3
Material connection
4
Material/blocking fluid
outlet
1
2
4
3
26/4
eldo100-029/0000000343-001-EN
Structure and function
4.2.11
Static discharge system ID 2/2 and ID 4/4
The discharge system opens or blocks the material discharge. On closing, a back
suction effect is generated which prevents dripping on the plastic mixer outlet. A
pneumatic drive cylinder simultaneously operates the valves for both components.
Switching over is performed by a solenoid valve. The components are fed in separately up to the mixing block outlet. Mixing is carried out in the plastic mixer. The
opening stroke and therefore also the back suction effect of the valve can be adjusted using the adjusting screw.
1
Plastic mixer
2
Spigot nut
3
Handle (option)
4
Non-return valve
5
Packing nut
6
Drive cylinder
7
Solenoid valve
8
Adjusting screw
9
Hexagon nut
1
4.2.12
2
3
4
5
6
7
8
9
Plastic mixer
The plastic mixer includes a mixing helix and is fixed to the discharge system with a
spigot nut. The components are mixed by shearing actions on the mixing helix.
As soon as the mixed material has hardened in the plastic mixer, it must be replaced.
The plastic mixers are available with different diameters and lengths. The respective
version is selected depending on the application.
Static mixing helix
1
Plastic mixer
2
Spigot nut
eldo100-029/0000000343-001-EN
1
2
4/27
Structure and function
4.2.13
Sealing cap
After work, the discharge channels can be sealed using the sealing cap. Before installing the sealing cap, it should be filled with a sealing medium such as Mesamoll
grease.
1
Mixer head
2
Sealing cap
3
Spigot nut
4.2.14
1
2
3
Diaphragm vacuum pump
The vacuum pump extracts the air from the material vessel (evacuation). The vacuum removes the air trapped in the material. In some applications, the vacuum can
also be used to refill the material vessels.
1
Collector vessel
2
Suction connection (rear)
3
Pressure gauge
4
Valve
5
Vacuum pump
6
Switch (rear)
7
Exhaust air sound absorber
1
2
3
4
5
6
When toxic gases or vapors escape, the exhaust air sound absorber should be replaced by a 1/8" threaded nozzle with a hose so that the exhaust gases may be led
away.
28/4
eldo100-029/0000000343-001-EN
Structure and function
4.2.15
Start trigger
The execution of a function can be triggered by pressing the start button on the touch
screen, by actuating an optional handle or foot switch or, optionally, by an interface
signal.
1
Start button
2
Handle button (optional)
3
Foot switch (optional)
1
4.3
2
3
Touch screen
The systematic menu structure is illustrated in the operating instructions by
way of sample pictures. These pictures may differ from the menus displayed
on the touch-screen depending on the machine configuration.
4.3.1
Display/navigation information
Navigation
Menu button status
Function button status
By pressing the
or
button, additional screens with setpoints and actual values are displayed.
When pressing the button of a menu, the button is highlighted. A highlighted button
signals that the selection has been made. The menu may be closed by pressing the
highlighted button once again.
The status of heating unit and agitator is indicated via the color of the respective button.
•
•
Gray: The function is OFF. The function may be switched on.
Green: The function is ON. The function may be switched off.
A complete overview of the menu structure with all its options can be found
as a file in the supplied data storage device.
4.3.2
Pictograms
Below is an overview of the pictograms used. See the corresponding chapter for a
detailed description.
eldo100-029/0000000343-001-EN
User logged in
Recirculation
User logged out
Pressure discharge
Overview
Heating
Diagnostics
Material hose heating
Parameterization
Vessel heating
4/29
Structure and function
ESC
Configuration
Pump heating
Status
Volume counter heating
Messages
Dispensing valve heating
Further contents
Mixer heating
Page down
Agitator
Page up
A component
Exit/Close
B component
Reset
Flow rate
Start
Time
Stop
Pump
Deselect function
Volume counter
Overview parameter groups
Vessel level
Continuous metering
Pot life
Shotwise metering
Filling
Metering by program data
De-aeration through discharge system
Pre-run
A
De-aeration through de-aeration
valve
Mixing ratio
Interpolate flow rate adjustment
Automatic mixing ratio adjustment
USB (activating/deactivating)
Flushing
30/4
eldo100-029/0000000343-001-EN
Structure and function
4.3.3
Main menu (start screen)
Main menu
In the main menu, you can find all important data and buttons for system operation.
The buttons for the pre-selection of the material discharge functions are located on
the left-hand side.
The process data are displayed at the center.
The buttons for the additional functions are located on the right-hand side.
Only the functions which are selectable in the current operating status are displayed.
By pressing the
Main menu
2
1
1
Status information
2
National flag for language
selection
3
Login key
4
Metering functions
5
Process data
4
6
Component-specific metering functions
5
7
Menu line
8
Additional functions
9
Component-specific additional functions
10 Overview
button, component-specific functions are displayed.
3
8
9
6
7
11 Diagnosis
10
11
12
13
14
15
12 Parameterization
13 Configuration
14 Status
20
16
15 Messages
17
Operating screen
16 Actual value
17 Setpoint value
18 Start button
19 ESC key
20 Selected function
18
19
The operating screen will be displayed after selecting a metering function.
The current process data are displayed on the operating screen.
The selected function is started by pressing the
button.
By pressing the "ESC" button, you may return to the main menu.
Setpoint values can be changed by touching the respective dark gray numeric field
(6.3 Changing setpoint values).
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Structure and function
4.3.4
Component-specific functions
Component-specific metering functions
The component-specific metering functions are displayed in the left section of the
Component-specific additional functions
The component-specific additional functions are displayed in the right section of the
32/4
main menu when the
button is pressed.
The functions can be carried out individually for each component..
main menu when the
button is pressed.
The functions can be carried out individually for each component..
eldo100-029/0000000343-001-EN
Structure and function
4.3.5
Overview
This menu gives an overview of the entire machine. The menu may be called up or
closed at any time by pressing the
button.
Overview
1
Scrolling
2
Current, central values
3
Dispensing valve
4
Level display
5
A component
6
Active status (green)
7
Current values of the
component
8
Metering data
9
Overview button
10 B component
1
2
3
4
5
6
10
7
8
9
In this diagram, the active system components, such as motors, pumps or valves,
are displayed in green. More process data are displayed by scrolling.
Process data
eldo100-029/0000000343-001-EN
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Structure and function
4.3.6
Diagnosis
On the "Diagnosis" menu screen, signal conditions can be monitored. The menu
may be called up or closed at any time by pressing the
button.
Diagnosis screen 1
1
No signal (gray)
2
Active input signal (green)
3
Diagnosis button
1
2
3
Diagnosis screen 3
1
Analog input signal bar
graph
2
Analog input signal numeric value
1
3
Output signal
2
4
No signal
3
4
Input signals are displayed in green.
Output signals are displayed in red.
The bar length shows the strength of the analog signal in addition to the numeric value.
The value for the pulses detected by the volume counter can be displayed. The volume counter values may be reset by pressing the
34/4
button.
eldo100-029/0000000343-001-EN
Structure and function
4.3.7
Configuration
Configuration
In the "Configuration" menu, you will find all data and settings as to the hardware
configuration. The menu may be called up or closed at any time by pressing the
.
The menu first displays the overview of the parameter groups. From the parameter
groups overview, a parameter group can be selected.
Overview parameter
groups
1
Parameter group
2
Configuration key
3
Login key
3
1
Parameter group
4
Scroll button
5
Parameter group name
6
Parameter name
7
Parameter value
8
Current page/total pages
9
Overview parameter
groups
2
10 Selection
4
5
8
6
9
7
10
The next parameter group is displayed by pressing the
By pressing the
or the
button.
button, you will return to the overview of the parameter groups.
To change a parameter value, you must log in first (4.3.11 Log-in).
In order to change a parameter value, press the field with the parameter value. The
keypad appears and the new value can be entered.
If the parameter value was not entered during commissioning and the displayed value is outside the permissible limits, the input field is displayed in yellow.
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Structure and function
4.3.8
Parameterization
Parameterization
In the "Parameterization" menu, you can find all data and settings important for operation. The menu may be called up or closed at any time by pressing the
ton.
but-
The menu first displays the overview of the parameter groups. From the parameter
groups overview, a parameter group can be selected.
Overview parameter
groups
1
Parameter group
2
Parameterization key
3
Login key
3
1
Parameter group
4
Scroll button
5
Parameter group name
6
Parameter name
7
Parameter value
8
Current page/total pages
9
Overview parameter
groups
2
4
5
8
6
9
7
The next parameter group is displayed by pressing the
By pressing the
or the
button.
button, you will return to the overview of the parameter groups.
To change a parameter value, you must log in first (4.3.11 Log-in).
In order to change a parameter value, press the field with the parameter value. The
keypad appears and the new value can be entered.
If the parameter value was not entered during commissioning and the displayed value is outside the permissible limits, the input field is displayed in yellow.
36/4
eldo100-029/0000000343-001-EN
Structure and function
4.3.9
Status
This menu gives an overview of the system status and possible system error causes. The menu may be called up or closed at any time by pressing the
button.
Status
1
Status OK
2
Fault position
3
Poor condition but no fault
1
4
Status button with signaling a fault
2
5
Status button with signaling a defect
3
6
Current page/total pages
6
4
3
5
eldo100-029/0000000343-001-EN
4/37
Structure and function
4.3.10
Messages
The system outputs information and error messages which must be acknowledged
by touching the current message. The error is thus acknowledged but not eliminated. It is possible that a fault position is displayed in the
All messages displayed so far are listed in the
"Status" menu.
"Messages" menu. The menu
may be called up or closed at any time by pressing the
button.
Messages
1
Current message
2
Status button
1
2
1
List with date and time
2
Messages button
3
Delete message list
1
2
3
Up to 100.000 messages are stored. If a new message is added to a full list, the oldest message is deleted automatically.
Delete messages
38/4
By pressing the "Delete" button, all messages are deleted from the list.
eldo100-029/0000000343-001-EN
Structure and function
4.3.11
Log-in
The menus
and
in the menus or if the
1
Log-in window
2
Input field
are protected with a password. If input fields are selected
button is pressed, the log-in window is displayed.
Login
User name
1
Pasword
2
Exit
Log-in
 Press the
button.
• The log-in window appears.
• The keypad appears.
 Enter user name.
 Enter the password.
 Confirm log-in by OK.
• The log-in window is closed.
• The
key indicates that a user is logged in.
Log-out
After the last entry, log-in remains active for the log-out time specified for the
user. During this period, the user can leave the menu and re-enter without login. Afterwards, the system logs off automatically.
 Press the
• The
eldo100-029/0000000343-001-EN
button.
button indicates that the user is logged out.
4/39
Structure and function
4.4
Selectable functions
4.4.1
Continuous metering
Pre-selector button.
Continuous material discharge with undefined volume. Depending on the parameterization, material is discharged as long as a start signal is pending or the material
discharge is started via a start signal and stopped by a second stop signal. During
discharge, the parameterized minimum metering time is taken into account.
4.4.2
Shotwise metering
Pre-selector button.
Shotwise material discharge with defined volume. The desired material quantity
must be entered directly. The function must be started by a start signal.
4.4.3
Programmed metering
Pre-selector button.
Metering by means of metering programs. The start signal triggers a sequence defined in the metering program. The desired metering quantity can be stored in the
metering program. When entering the value 0 for the metering quantity, material will
be discharged continuously.
4.4.4
Pre-run
Pre-selector button.
During the pre-run, a defined quantity of material is discharged in order to re-fill the
mixer. A pre-run is required e.g. after rebooting the machine, after a mixing ratio
check, after flushing, after a potlife regeneration error or after a mixing ratio error.
4.4.5
Mixing ratio inspection
Pre-selector button.
Function for checking the mixing ratio. Both material components are simultaneously discharged at the mixing ration set. The discharged material must be collected
separately for weighing purposes.
4.4.6
Recirculation
Pre-selector button.
The material is delivered from the material vessel through the gear pump back into
the material vessel. The circulation of the material in the circuit prevents any fillers
contained in the material from settling. If heating is provided, recirculation is used to
distribute the temperature evenly in the material-contacting components.
The delivery capacity for recirculation must be parameterized on the control unit.
The started function runs until a stop signal occurs. Depending on the parameter setting, recirculation can also run in the interval mode.
40/4
eldo100-029/0000000343-001-EN
Structure and function
4.4.7
Discharge pressure
The function is used to discharge the material pressure. The outlet system is
opened.
4.4.8
Automatic mixing ratio adjustment
Pre-selector button.
A
Function for determining the flow rate adjustment values. Both material components
are simultaneously discharged at the mixing ration set. Discharge is carried out in
multiple steps with different machine capacities. The determined values for the flow
rates are stored in the menu
4.4.9
.
Interpolating flow rate adjustment
The determined values or the values entered in the menu
ment must be interpolated by pressing the key.
4.4.10
for flow rate adjust-
De-aeration
Pre-selector button.
Function for de-aeration of the machine with opened or closed discharge system.
When pre-selecting the function with the discharge system closed, a de-aeration
valve must be opened manually.
4.4.11
Stirring
Agitators in the material vessel prevent settling of fillers during downtimes and ensure an even temperature distribution.
The running time and the downtime can be parameterized on the control unit. The
interval of a started agitator function always starts with the running time.
4.5
Checks carried out automatically
4.5.1
Pressure monitoring
Pressure sensors measure the material pressure at the outlets of the gear metering
pumps. The pressure is displayed on the operating screen of the control unit.
The pressure limits must be parameterized on the control unit.
4.5.2
Potlife check
Potlife is the time between the homogeneous mixing of the components and the last
possible time of use. The potlife depends on the material and must be entered as a
parameter. The control unit checks and issues a signal after metering when the potlife has expired. When the potlife has expired, the plastic mixer must be replaced or
regenerated.
eldo100-029/0000000343-001-EN
4/41
Structure and function
4.5.3
Metering quantity monitoring
After a metering process, a volume counter checks whether the delivered material
quantity lies within the specified tolerance range.
4.5.4
Mixing ratio inspection
The volume counters exactly record and control the mixing ratio of the components
and the material amounts delivered. In case of deviations beyond the tolerance, the
material discharge is stopped and the machine issues an alarm.
The mixing ratio, its tolerance and the test quantity must be parameterized on the
control unit.
4.5.5
Filling level check
Rod probes in the material vessels measure their filling level. The filling level is
shown on the working screen of the control unit.
Level check must be parameterized on the control unit. When falling below the minimum level, the control unit issues an error message.
4.5.6
Regeneration
This function is used to flood the plastic mixer with newly mixed material upon expiration of the potlife. The control unit requires a digital input signal which confirms that
the exhaust is in the regenerating position.
The system capacity and the regeneration amount or time must be parameterized
on the control unit.
4.5.7
Leakage check
If a volume counter detects impulses during metering pauses, this is a sign for a possible leakage in the system.
The number of permitted leakage impulses must be entered during parameterization.
4.5.8
Operating data recording
The operating data can be saved on a USB stick. When saving, the file "DAQ.csv"
is created. Saving is always executed after shotwise metering, continuous metering
or in case of a malfunction. Operating data are, e.g.:
•
•
•
•
•
•
•
•
42/4
Date and time
Metering program no.
Function
Material pressures
Mixing ratio set value and actual value
Metering quantity actual
Material consumption
Error/status messages
eldo100-029/0000000343-001-EN
Structure and function
Technical data
4.6.1
Dimensions
H3
H2
H1
4.6
T1
T2
B1
B2
4.6.2
Dimensions
1
2
3
Height H
750 mm
1,730 mm
2,190 mm
Width B
806 mm
1,000 mm
Length/Depth T
1,000 mm
1,500 mm
Empty weight G
240 kg
Electrical connection
Electrical connection
Machine
Mains voltage
400 V 3/N/PE
Frequency
50 Hz
Power consumption I nom
12 A
Nominal output
1.6 kW
Max. switching capacity Isich
1 kA
Connection
CEE connector 16 A
eldo100-029/0000000343-001-EN
4/43
Structure and function
4.6.3
Ambient conditions
System operation
System operation (without material)
Air temperature
+ 5 to + 40 °C
Relative air humidity
max. 85% (non-condensing)
NOTICE
Reduction of motor output.
In case of operation at heights above 1000 meters above sea level, the motor output
is reduced by 1% per 100 meters.
► Note the height above sea level when operating the system.
Transport and
Storage
Transport and storage (without material)
Material processing temperature
Air temperature
- 25 to + 55 °C
Relative air humidity
max. 85% (non-condensing)
For all operations, the material must be brought to the correct processing temperature. This temperature is to be considered, if:
•
•
•
the material is taken out of cold storage,
heating is provided to heat up the materials,
cooling is provided to cool down the materials.
NOTICE
Processing temperature of the material.
The material must be brought to the correct processing temperature in order to avoid
mixing and metering faults.
► Observe the notes on temperature in the material data sheet.
4.6.4
Gear metering pump
The gear pumps can be fitted with different sealing systems.
44/4
Type
Name
Max. intake pressure
URF
High-pressure seal
150 bar
RSS
Triple shaft seal
6 bar
VCR
V-shaped seal
20 bar
MSE
End face mechanical seal
15 bar
eldo100-029/0000000343-001-EN
Structure and function
4.6.5
MR40
Structure
1
Programming interface
2
Ethernet interface LAN
3
Interface CAN1
4
USB port
5
Digital inputs
6
Digital outputs
7
CAN2 interface
8
Interface COM1
9
Interface COM2
10 Fieldbus (option)
11 Status LED fieldbus (option)
1
2
3
4
5
10
6
11
7
Terminals I/O assignment
X1
9
X5
X7
1
L+
25
AI0+
49
DI0
73
DO0
2
M
26
AI0-
50
DI1
74
DO1
3
L+
27
FE
51
DI2
75
DO2
4
L+
28
AI1+
52
DI3
76
DO3
5
L+
29
AI1-
53
DI4
77
DO4
6
24V_DO_G1
30
FE
54
DI5
78
DO5
7
24V_DO_G2
31
AI2+
55
DI6
79
DO6
8
MI
32
AI2-
56
DI7
80
DO7
9
MI
33
FE
57
DI8
81
DO8
10
MI
34
AI3+
58
DI9
82
DO9
11
M_DI_G1
35
AI3-
59
DI10
83 DO10
12
M_DI_G2
36
FE
60
DI11
84 DO11
X2
eldo100-029/0000000343-001-EN
X3
8
X4
X6
X8
13 AA0+
37
AI4+
61
DI12
85 DO12
14
AA0-
38
AI4-
62
DI13
86 DO13
15
FE
39
FE
63
DI14
87 DO14
16 AA1+
40
AI5+
64
DI15
88 DO15
17
AA1-
41
AI5-
65
GI16
89 DO16
18
FE
42
FE
66
GI17
90 DO17
19 AA2+
43
AI6+
67
GI18
91 DO18
20
AA2-
44
AI6-
68
GI19
92 DO19
21
FE
45
FE
69
GI20
93 DO20
22 AA3+
46
AI7+
70
GI21
94 DO21
23
AA3-
47
AI7-
71
GI22
95 DO22
24
FE
48
FE
72
GI23
96 DO23
4/45
Structure and function
Legend
Terminal
Description
Terminal L+
Power supply +24V
24V_DO_G1
Digital outputs supply DO0...DO11
24V_DO_G2
Digital outputs supply DO12...DO23
M
Power supply 0V
MI
Internal 24V ground
M_DI_G1
Ground for primary circuit digital inputs DI8...DI15
M_DI_G2
Ground for primary circuit digital inputs
DI16...DI23
FE
Functional earth
M connected to M_I
M_DI_Gx connectable to M_I
with plug-in jumpers
DI0...DI23
Digital inputs
DO0...DO23
Digital outputs
AI0...AI7
Analog inputs
Non-floating (common ground)
AIx + = signal supply line
AIx - = signal return line (AGND)
AO0...AO3
Analog outputs
Non-floating (common ground)
AOx + = signal supply line
AOx - = signal return line (AGND)
Housing data
External dimensions W x H x D [mm]
Installation section W x H [mm]
Weight [kg]
Protection rating, installed condition
215 x 120 x 45
184.8 x 101.5
0,5
IP 10
Nominal voltage
Power consumption
DC 24 V +/- 10%
0,3 A
Program memory
2 MB Flash
Main memory
2 MB SRAM
Data memory
1 MB Flash
Supply voltage
Memory
32 kB FRAM
46/4
eldo100-029/0000000343-001-EN
Structure and function
Interfaces
Programming interface SWD/ETM
USB 1.1
RS232
RS422/RS485
2x CAN V2.0B
Ethernet 10/100 base-T
Field bus (option, different versions)
Inputs and outputs
Digital inputs
24
Digital outputs
24
Analog inputs
8, 0...10 V, 0/4...20mA
Analog outputs
4, 0...10 V or 0/4...20mA
Controller
STM32F429NIH
Other
Core: ARM Cortex-M4
Programming language
"C" high-level language
Operating system
Real-time multitasking operating system CMSIS-RTOS
Permitted ambient temperature
0...50 °C
Time/Date
Real-time clock
Buffer battery service life
min. 3 years
(reference Varta CR1220 3V, 35mAh)
eldo100-029/0000000343-001-EN
4/47
Structure and function
48/4
eldo100-029/0000000343-001-EN
Commissioning
5
Commissioning
5.1
Transportation
The machine is packaged and delivered by the manufacturer in a proper manner. It
is protected for transport and against weather conditions, and provided with suitable
packaging materials.
DANGER
Transporting the system incorrectly could result in personal injury!
Fatal injury could result if the system is transported incorrectly.
► Transport the system with the help of persons who are forklift-trained and who
are able to handle heavy items.
Transport the system to final destination as packaged and only remove package before first use. The packaging protects the system.
5.2
Operating location
At the operating location, the weight of the system and the local protection provisions are to be observed. Easily inflammable materials (e.g. solvents) require special care.
Observe the following points:
•
•
•
•
•
•
•
•
•
5.3
Check the ground's bearing capacity.
Check space conditions and accessibility.
Observe local regulations concerning safety and protection.
Attach safety signs.
Have protective clothing available.
Check thermal conditions (if the system is equipped with heating system).
Ensure adequate ventilation when working with toxic fumes and vapors.
Ensure that air conditioning keeps the environment dry.
Provide space for fresh air supply and exhaust air with aerated control cabinet.
Removing packaging
Disposal
All packaging material must be removed with care. Packaging material must be disposed of in the correct manner (see chapter 8 Disposal).
Warranty conditions
The system must be checked for damage that may have occurred in transit. If damage is found, then the warranty conditions must be observed. The warranty conditions are described in the sales documents.
eldo100-029/0000000343-001-EN
5/49
Commissioning
5.4
Raising/Relocating
The table version has four through holes on the chassis. Ring bolts can be fastened
to them to lift the machine.
1
Ring bolt
2
Through holes
1
2
WARNING
Improper loading can cause the ring bolts to break the the machine could fall.
If the machine falls, it can cause serious or fatal injuries.
► Ensure the permitted loading direction when assembling the ring bolts.
5.5
Installation
The system must be installed and operated on a level floor. If the system or parts of
it are fitted with rollers and are free to roll then a roller brake must be fitted to prevent
accidental movement. Additional securing is not necessary. All system parts must
be installed on a non-slip base. Observe the local ergonomic principles for workplaces.
The system has been designed for operation in spaces that are protected from
weather effects. Operation and storage in an environment containing aggressive
substances or too high humidity or outdoors will result in corrosion damage, for
which the manufacturer does not assume liability.
NOTICE
The access to the cooling openings must be free, so that the cooling air can
flow in the inside of the housing.
In case of overheating, components can fail or be damaged.
► The main emergency stop button must always be freely accessible.
50/5
eldo100-029/0000000343-001-EN
Commissioning
5.6
Connection
5.6.1
Electrical connection
The smachine with its electrical components such as touch screen, agitator, heating
etc. requires an appropriate connection to a power supply (see circuit diagrams
chapter). The control cabinet must be grounded on the bolt provided for this purpose.
DANGER
Danger of electric shock!
Touching parts in this danger zone may result in serious or fatal injury from electric
shock.
► Work on power supply systems may only be performed by qualified electricians.
All grounding connections or equipotential bonding strips on the machine or on its
modules must be connected to the earth potential of the user's device.
According to EN 60204-1, in case of a leakage current higher than 10 mA in machines with variable-speed drives, these must be grounded with an equipotential
bonding conductor of 10 mm² Cu if the protective conductor of the machine's supply
line is smaller than 10 mm² Cu.
Ground connections can also be located on pumps to dissipate electrostatic
charges.
1
Ground connection
2
Connecting cable to equipotential bonding
1
2
5.6.2
Compressed-air connection
The machine must be connected to a compressed air supply. The supply line must
have a bore diameter corresponding to the technical data for a constant pressure
delivery of 6 bar. For pneumatic drives, air cylinders, valves and to fill in the material
vessels, the compressed air must comply with the quality level 3 according to DIN
ISO 8573-1.
eldo100-029/0000000343-001-EN
5/51
Commissioning
5.7
Vacuum pump exhaust air
During evacuation, gases and vapors are released from the material. These gases
may be more or less hazardous depending on the material. In any case, the gasses
and vapors which are discharged at the outlet of the vacuum pump should be led
away properly.
If necessary, install an exhaust gas hose at the outlet of the vacuum pump by means
of a gas-tight connection and lead the exhaust gases away via an extraction device.
Also observe the notes in the operating instructions of the vacuum pump (see chapter Accompanying documentation).
WARNING
Danger due to inhalation of toxic vapors!
Inhaling toxic vapors may be harmful to your health and lead to unconsciousness.
► Potentially harmful gases and vapors must be led away at the outlet of the pump.
5.8
Basic inspection
Inspection must be carried out during initial commissioning and after repair work. It
is done without material (material vessel and lines empty).
Checking the system
 Carry out visual inspection.
 Open the compressed air supply.
 Check components and hoses for air leaks.
Check the pipe fittings
 The pipe fittings could become loose when transporting the system.
 Check the pipe fittings and tighten them if necessary.
Checking the sealing systems
Adjustable seals may be provided in the discharge system, the shut-off valves or the
metering pumps. For more information on the sealing systems, see chapter Maintenance (7.2 Maintenance of the modules).
 Check the gland nuts and tighten them if necessary.
Checking the seals
 Listen for leaks in the pneumatic lines.
The leakage detector (LEAK_DETECT) can be used to find leakage which cannot
be heard. This device can be purchased from Hilger u. Kern. For detailed information on the device, go to www.hilger-kern.de.
5.9
Switching on
Switching on the system
 Turn on the main switch.
 Open the compressed-air main valve on the compressed-air maintenance unit.
 Set the pressure on the compressed-air maintenance unit to max. 6 bar.
 Confirm and acknowledge any error messages (4.3.10 Messages).
5.10
Language selection
By pressing the country flag, the language can be changed anytime on the touchscreen.
52/5
eldo100-029/0000000343-001-EN
Commissioning
5.11
Enter data
Data must be entered in the menu
and
during commissioning.
 Press the
or
button.
• The parameter groups are displayed.
 If the menus are password protected, login (4.3.11 Log-in) is required.
 Press the button with the name of the desired parameter group.
• The
parameter
names
and
their
values
are
(5.14 Parameterization).
 The next parameter group is displayed by pressing the
or the
displayed
button.
 Press the field of the parameter value.
• The keypad appears.
• The limit values are displayed using the keypad.
1
Limit values
2
Keyboard
3
Return
4
Close
5
Input value
4
5
1
2
3
 Input the setpoint using the keypad.
 Press the Return button.
• The keypad disappears.
• The new value is only saved it it is within the limit value.
 By pressing the
button, you will return to the parameter groups.
• Further parameter values can be entered.
 Press the
eldo100-029/0000000343-001-EN
or the
button to exit the menu.
5/53
Commissioning
5.12
Configuration
The settings in the
menu affect the hardware and should only be undertaken by
qualified maintenance personnel. The following configurations may be changed on
this installation:
NOTICE
Changes in the configuration menu
Changes made to this menu can result in faults.
► Parameters may only be adapted in cooperation with the DOPAG Service.
If you want to access this menu, you have to enter the user name and password (see chapter 5.13 User administration).
General settings
54/5
•
Start signal deaering
Selection whether the start signal during de-aeration is to be carried out statically
or as an impulse (start/stop).
•
Start signal metering continuously
Select whether the start signal during continuous metering is to be carried out
statically or as an impulse (start/stop).
•
Start signal on site
Selection of functions than can be executed by a start signal on site. All other
functions must be started on the touch-screen.
•
Stop signal on site
Determines whether the stop signal on site only stops the running function or it
stops and deselects it.
•
Program selection mode
Determining whether the metering programs should be selected using the touch
panel, through the (external) interface or the fieldbus connection.
•
Setpoint specification
Select whether the value for the machine capacity is taken from the metering
program or whether it is defined by an analog signal (analog) by the customer or
by the fieldbus connection.
•
Unit potlife
Determining whether the time is to be displayed in seconds or minutes.
•
Flow rate adjustment metering program
Select whether the values for flow rate adjustment from the metering program or
from the machine configuration shall be used.
•
Min. dose time metering continuously
A minimum metering time can be defined for continuous metering, which prevents metering extremely small amounts. Metering extremely small amounts
can lead to a mixing ratio offset. The minimum metering time depends on the application.
•
Data logging
eldo100-029/0000000343-001-EN
Commissioning
Selection whether operating data recording shall be on or off.
Pressure control
Pumps
Volume counter
Delay times
Leakage
•
Logging cycle
Memory cycle of the operating data recording.
•
Pressure sensor 20 mA
Upper limit in the pressure sensor measurement range.
•
Max. working pressure
Maximum permitted material pressure within the system.
•
Pressure increasing
Control time for the pressure control.
•
Pump size
Gear metering pump size.
•
Max. pump speed
Maximum permitted metering pump speed due to design.
•
Pulse value
Value that depends on the volume counter type (5.23 Adjusting the volume
counter).
•
Max. down time
Control time. If there are no impulses from the volume counter in time during metering, an error message is issued.
•
Outlet/Circulation OPEN - block/inlet OPEN
Delay time between opening the exhaust or the recirculation and opening the
cut-off or inlet valve on the gear metering pump.
•
Block/inlet OPEN - Pumps ON
Delay time between opening the cut-off or inlet valve on the gear metering pump
and starting the gear metering pump.
•
Pumps OFF - block/inlet CLOSED
Delay time between stopping the gear metering pump and closing the cut-off or
inlet valve on the gear metering pump.
•
Block/inlet CLOSED - Outlet/circulation CLOSED
Delay time between closing the cut-off or inlet valve on the gear metering pump
and closing the exhaust or the recirculation.
•
max. leakage pulses
Permitted number of impulses of the volume counter during metering pauses.
This parameter is used for leakage control.
•
Leakage control time
After the time has expired, the counted leakage pulses are reset to zero.
•
Max. channel deviation
Maximum allowable difference of the impulses from channel 1 and channel 2 of
the volume counter.
•
Delay detection OFF after metering
Leakage control does not start until the parameterized time after metering has
been completed has elapsed.
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Commissioning
Level control
•
Residual quantity
Information on level control of the material vessel. When the 0% level is reached
according to the measurement of the level probe, an undetected residual quantity remains in the vessel. This value must be determined. The metering process
can be resumed until the residual quantity has been consumed.
In the table below, the residual quantities in the material vessels for the different level
probes used are defined. If different vessels or level probes are used, the residual
quantity values may vary.
Article No.
Material vessel
Bar length
Level probe
Residual quantity
Bar length
Level probe
Vessel size
with agitator
21300368
165 mm
0,7 l
No level probe possible
12 l, Di=284 mm 22023144
220 mm
2,5 l
170 mm
5,7 l
24 l, Di=284 mm 22023145
380 mm
2,3 l
330 mm
5,5 l
45 l, Di=284 mm 22023146
730 mm
2,5 l
650 mm
7,6 l
60 l, Di=284 mm 22026871
950 mm
2,5 l
900 mm
5,7 l
60 l, Di=362 mm 22031503
580 mm
7,5 l
520 mm
13.7 l
4 l, Di=163 mm
Residual quantity
without agitator
The lowermost switching point of the level probe is located 15 mm above the end of
the level probe. For materials of higher viscosity, a smaller value should be entered
for the residual quantity since, in case of a larger residual quantity, material might
stick to the walls of the vessel and not flow off.
1
Level probe
2
Residual quantity
3
Material vessel
1
2
3
External flow rate
56/5
•
Flow rate at 4 mA / 2 V and flow rate at 20 mA / 10 V
When specifying the flow rate via an analog signal. Determining which signal intensity of the analog signal corresponds to which flow rate.
•
Delay analog change
The control unit only reacts to analog values for changing the flow rate that are
present upon expiration of the period of time.
•
Min. change analog value
If any changes are made to the flow rate during metering, it is not executed until
the value for the minimum change is reached.
•
Flow rate changing step
eldo100-029/0000000343-001-EN
Commissioning
If any changes are made to the flow rate during metering, it is gradually carried
out according to the percentage value.
Flow rate adjustment
A correction value can be entered for different flow rates. Any change of the flow rate
of a component will result in a change of the mixing ratio.
Touch screen
•
Date/Time
The date and time can be set.
•
Brightness
The display brightness can be changed here.
•
Calibration
The touch screen can be newly calibrated (7.3 Calibrate touch-screen).
•
Load
Key for loading a new software for the touch screen.
•
Quit RT
Button for exiting the program running on the touch screen.
•
Reboot
The touch screen software is rebooted. After specific software-related interventions, you may be requested to start a booting procedure.
•
Documentation
The documentation for the metering computer can be opened for reference.
PLC
User administration
Users can be created or deleted (5.13 User administration).
Machine information
•
Software
The software number is displayed.
•
Manual
The operating instructions can be opened for reference.
5.13
1
Password
2
User
3
Empty line
User administration
4
Configuration key
5
Group (authorization)
6
Log-out time
5
1
6
2
3
4
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Commissioning
User and password
User name and password can be adjusted to your needs. The following users may
be factory-preset:
User
Password
Group
Authorization
admin
not published
Admin
Master password for the manufacturer No
PLC
User
not published
Unautho- System-dependent user
rized
user
1111
User
2222
Service
No
Password for staff members to autho- Yes
rize them to edit data in the parameterization
service
Editable
menu.
Password for maintenance staff mem- Yes
bers to authorize them to edit data in
the parameterization
and configu-
ration
menus and to create and
delete users.
Create user
 Press the
button.
 Press the "User administration" button.
• The users list is displayed.
 Touch the first field in the empty line.
• The keypad appears.
 Enter the new user name and confirm it.
 Touch the empty field for the password.
• The input field is opened.
 Enter the password. The password must have four characters at least.
 Enter the password again for acknowledging purposes and confirm it.
 Select the authorization in the Group field.
 Enter the log-out time.
Delete user
 Press the
button to exit the menu.
 Press the
button.
 Press the "User administration" button.
• The users list is displayed.
 Touch the line of the user to be deleted.
• The keypad appears.
 Press the "Del" button.
• The user is deleted.
 Press the
58/5
button to exit the menu.
eldo100-029/0000000343-001-EN
Commissioning
5.14
Parameterization
The parameters must be checked and set in the menu
during commissioning.
If you want to access this menu, you have to enter the user name and password (see chapter 5.13 User administration).
Metering program
Mixing ratio
Pre-run
Any possible parameters of the series are listed and described in the following list.
Parameters which are not needed due to the special configuration of the machine
are not displayed on the screen.
• Program No.
Number of the metering program.
•
Program name
Name of the metering program.
•
Quantity
Amount of mixed material to be discharged. If the value "0" is entered, continuous metering is carried out (without amount limit).
•
Flow rate
Discharge capacity of mixed material.
•
Tolerance overflow
Tolerance of the delivery quantity. When the tolerance is exceeded, an error
message is issued.
•
Max. metering time
Control time. If the system exceeds the entered time period, an error message
is issued.
•
Flow rate adjustment
A correction value may be entered for the flow rate.
•
Setpoint 100
Mixing ratio per volume parts according to the material manufacturer's specifications.
•
Tolerance +/Permitted tolerance of the mixing ratio according to the material manufacturer's
specifications.
•
Checksize
The mixing ratio is checked several times during the metering process. The
check is always executed when the test quantity is reached. The test quantity
must be smaller than the pre-run quantity.
•
Quantity
Amount of mixed material to be discharged during pre-run.
•
Flow rate
Delivery capacity of mixed material during pre-run.
•
Max. metering time
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Commissioning
The maximum metering time is greater than the theoretical metering time. If the
time is exceeded when executing the pre-run function, an error message is issued.
MR control
Deaering
Recirculation
Potlife control
60/5
•
Max. errors
If mixing ratio errors occur during pre-run, the pre-run operation is automatically
executed until the mixing ratio is correct or the number of maximum errors during
pre-run is reached.
•
Quantity
Combined amount of components A and B to be output during mixing ratio
check.
•
Flow rate
Material delivery capacity in the corresponding mixing ratio during mixing ratio
check.
•
Max. metering time
Control time. If the metering time during the mixing ratio check is exceeded, an
error message is issued.
•
Flow rate
Delivery capacity during de-aeration.
•
Metering time
Time period for the de-aeration function. If the value 0 is entered, the started
function runs until a stop signal occurs.
•
Flow rate
Delivery capacity during recirculation.
•
Component
Select whether the circuit of A, B or A and B component is to be activated.
•
Active time
Recirculation runtime until the idle time.
•
Idle time
Idle time up to the next automatic start of recirculation. If the value 0 is entered,
recirculation runs permanently without a pause.
•
Potlife setpoint
Enter the potlife according to the material manufacturer's specifications.
•
Mixing volume
Amount of material needed for regeneration of the plastic mixer. As soon as the
quantity has been discharged during a metering process, the potlife is reset.
•
Flow rate
Delivery capacity of mixed material during regeneration.
•
Control time
Control time. If the regeneration position is not reached after the potlife and the
control time have expired, an error message is issued.
•
Max number cycles
eldo100-029/0000000343-001-EN
Commissioning
At the most, the automatic regeneration is performed until the set amount has
been reached. After this, a flushing process with A component is carried out.
Pressure control
Level control
Agitators
Data management
•
Max. metering time
Control time. If the time is exceeded when executing the regeneration function,
an error message is issued.
•
min./max. pressure
Material pressure control at the gear pump outlet. When the value exceeds or
falls below the limit, an error message is issued.
•
Delay time underpressure
If the supply pressure briefly drops e.g. at changeover positions of the delivery
pump, the pressure control is ignored for the parameterized amount of time.
•
Negative pressure fade out time
Before the metering pumps start, there is possibly no material pressure yet at
the pump outlet. Thus, the pressure limit check starts after the fade out time.
•
Low level
Minimum filling level value in the material vessel. An alarm is issued when falling
below the value.
•
High level
Filling level of the material vessel at which the refill process is stopped.
•
Active time
Agitator running time until idle time.
•
Idle time
Pause time up to the next automatic start of the agitator. If the value 0 is entered,
the agitator runs permanently without a pause.
The machine data, i.e. all settings carried out in the "Parameterization" and "Configuration" menus, can be saved to and restored from a USB stick (7.6 Machine data).
The parameter list can be saved to a USB stick (7.7 Data storage).
5.15
Setting the level probe
The level probes are factory preset. They can be adapted to the containers and the
production requirements.
A detailed description is attached as a separate document in the chapter Accompanying documentation.
The level probe must be set at operating temperature. If the difference between setting and operating temperatures is too big (±5°C), the level probe
could be inaccurate.
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Commissioning
Operating mode (MODE)
2
Save (SET)
3
Setting key (UP/DOWN)
4
Level display
5
Maximum level calibration
6
Switching output
7
Analog output
8
Minimum level calibration
9
Electronics module
10 Measuring range
4
9
1
5
6
X
1
2
10
7
11
3
8
15 mm
11 Probe rod
Reset
Execute a reset before the first compensation is carried out or before using the new
medium.
 Hold the keys MODE and UP/DOWN pressed simultaneously for 5 s.
• Level displays 0% and 100% illuminate, and % display flashes.
• Release the keys within 3 seconds.
 Press the UP/DOWN button and hold it while pressing the SET button simultaneously until all green LEDs light up for approx. 1 second.
 Press the MODE button five times.
• Reset is accomplished.
Calling the setting mode
 Hold the keys MODE and UP/DOWN pressed simultaneously for 5 s.
• Level displays 0% and 100% illuminate, and % display flashes.
• Release the keys within 3 seconds.
Minimum level calibration
 Press the key MODE several times until MN display illuminates and % display
flashes.
 Fill the container to between 5% and 25% of the desired measuring area.
 Set the value corresponding to the level with the key UP/DOWN.
 Press the SET button to save the setting.
• Permanent illumination, the value confirmation occurs after a few seconds.
Maximum level calibration
 Press the key MODE several times until MX display illuminates and % display
flashes.
 Fill the container to between 25% and 95% of the desired measuring area.
 Set the value corresponding to the level with the key UP/DOWN.
 Press the key SET to save the setting.
• Permanent illumination, the value confirmation occurs after a few seconds.
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eldo100-029/0000000343-001-EN
Commissioning
5.16
Filling (material vessel)
The material vessels must be filled with material. Afterwards, the material (depending on the machine configuration) must be heated, stirred, evacuated and the machine must be de-aerated.
Note the following before starting:
•
•
•
•
Agitators on the vessel covers must be turned off and isolated from the mains
supply.
Only use perfect and clean material.
Under no circumstances, may the two components be confused.
Fill the container on the previous evening in order to let escape the air over night.
WARNING
Hazard caused by abrupt starting of agitator!
When getting near rotating agitator vanes with the limbs, there is hazard of serious
injuries such as fracture, contusion or skin injury.
► Before opening the material vessel, the power connector must be disconnected
from the agitator motor.
WARNING
Hazard caused by spattering material!
When being filled in, material can spatter and cause eye injuries and skin lesion.
► Wear eye protection and protective gloves.
Preparation of filling operation
 Switch off the agitator.
 Disconnect the power supply connector from the agitator motor.
 Close the air shut-off valve of the vessel fitting.
 Open the air outlet valve.
• Air escapes.
 Close the air outlet valve when the pressure has equalized.
 Loosen the star knob bolts on the vessel lid manually.
 Remove the lid.
Filling
NOTICE
The material components must not be confused under any circumstances.
Mixing of material inside the vessel may lead to substantial damage.
► Make sure that the vessel is filled with the correct component.
NOTICE
Overfilled material vessels may damage parts of the compressed air system.
If the material vessels are overfilled, there is the risk that material enters the compressed air lines and causes damage to parts of the compressed air system.
► If the material is to be evacuated, fill the material vessel half way; otherwise, fill
it to max. 5 cm below the vessel edge.
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Commissioning
 Fill the material vessel.
• If possible, allow material to run down the vessel wall.
 To adjust the level probe, first fill in material until the end of the level probe is
covered by 2 cm of material and then perform the minimum-level calibration on
the probe. Continue filling the vessel and then perform the maximum level calibration.
 Clean the vessel edge, seal and cover.
 Lubricate the seal (silicone oil or petroleum jelly).
 Fit the lid.
 Hand tighten the star knob bolts.
End filling
 Reconnect the power supply connector to the agitator motor.
 Open the air shut-off valve of the vessel fitting.
 Adjust the pressure regulator for vessel pressure on the vessel fitting.
 Open the shut-off valve on the vessel outlet.
5.17
Evacuation
After filling up the material vessel, it must be evacuated.
 Switch on the agitator if necessary.
 Close the vessel outlet shut-off valve.
 Close the vessel outlet shut-off valve (in case of manual shut-off valve).
 Close the air shut-off valve on the vessel fitting.
 Open the air outlet valve.
 Wait until the pressure gauge for the vessel pressure indicates 0 bar.
 Close the air outlet valve.
 Pull off the vessel fitting on the coupling.
 Attach the air coupling of the vacuum pump.
NOTICE
If the material is initially evacuated with the lowest absolute pressure, the material may foam so intensely that the foam is sucked into the collector vessel
or the vacuum pump.
This may lead to clogging of the collector vessel or damage the vacuum pump.
► Carry out evacuation gradually.
It is recommended to evacuate with consistent pressure graduation in three steps
for 10 minutes each. Pressure steps example (absolute pressure values):
•
•
•
1st step 600 mbar
2nd step 300 mbar
3rd step 10 mbar
NOTICE
The evacuation values must be met.
If they are not met, the material properties could change.
► Never use a value below the permissible evacuation value for the material.
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Commissioning
 Switch on the switch on the vacuum pump.
 Observe the displayed pressure during evacuation.
 If necessary, regulate the underpressure at the vacuum pump valve.
 Observe the evacuation time.
 Observe the hose from the vessel to the vacuum pump. If material or foam is
sucked into the hose, the pressure must be increased until the material bubbles
have settled.
 Carry out the next evacuation step.
 Switch off the switch on the vacuum pump.
 Remove the air coupling of the vacuum pump.
• The material vessel is aerated.
 Plug the vessel fitting.
 Open the air shut-off valve on the vessel fitting.
 Open the vessel outlet shut-off valve.
5.18
De-aerating the gear pump
The gear pumps must be de-aerated during commissioning. Air in the system causes metering errors.
1
De-aeration screw
2
Sealing system
3
Gear metering pump
1
2
3
NOTICE
Operation of the transfer pump without material is only permitted for a short
period.
Prolonged operation of the transfer pump without material can cause damage to the
system.
► Make sure that the pump is only operated with 10% to 20% of its max. capacity
until it is filled completely.
WARNING
Risk of splashing!
The material is released under high pressure and spraying may occur due to entrapped air.
► Wear safety goggles and protective gloves! Observe the material manufacturer's safety information.
De-aerating the gear
pump
 Attach a transparent hose to the de-aeration screw.
 Hold the hose into a waste container.
eldo100-029/0000000343-001-EN
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Commissioning
 Slowly release the de-aeration screw.
• Air and material flow through the de-aeration.
 Tighten the de-aeration screw as soon as material free of air or bubbles is discharged.
5.19
De-aeration
The system must be de-aerated during commissioning, after refilling the material
supply, after maintenance work on pumps and supply lines and each time after unscrewing pipe fittings between material supply and discharge system. Air in the system causes metering errors.
NOTICE
There may be production residues or test material in the machine unless the
machine has been run in with original material.
During the initial use of the machine, such residues may result in defective products!
► During initial de-aeration, make sure to discharge sufficient material so that any
production residues or test material is flushed out thoroughly.
Requirements:
•
•
•
De-aerate the system
The machine must have been filled.
Depending on the machine configuration, the material must be stirred, heated,
or evacuated.
No plastic mixer and no end cap may be fitted to the discharge system.
 Press the
button on the left.
• Additional functions are displayed.
 Press the
button for the relevant component.
• Pre-selection for de-aeration with closed exhaust is active.
 Hold the collector vessel under the de-aeration valve.
 Open the de-aeration valve.
 Press the
button.
• Material is discharged.
 Release the
button or press the
or bubbles is discharged.
button as soon as material free of air
 Close the de-aeration valve.
 Press the
ESC
button to deselect the function.
 If there is more than one air relief valve, repeat this procedure.
De-aerate the discharge
system
 Press the
button on the left.
• Additional functions are displayed.
 Press the
button for the relevant component.
• Pre-selection for de-aeration with opened discharge system is active.
 Place a collector vessel under the discharge system.
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Commissioning
 Press the
button.
• Material is discharged.
 Hold the outlet system up so that the hose package rises from the system to the
outlet system. Rotate the outlet system during de-aeration so that the air can
easily escape towards the outlet.
 Release the
button or press the
or bubbles is discharged.
 Press the
ESC
button as soon as material free of air
button to deselect the function.
 Clean the mixer head with a cloth.
 Execute the process for the second component.
5.20
Flush the de-aeration valve
After the de-aeration valve has been operated, the sealing area must be flushed with
a blocking fluid.
 Install the grease gun at the lubricating nipple (4.2.10 De-aeration valve with
blocking attachment).
 Press in one or two strokes of grease.
 Collect leaking blocking fluid with a cup.
eldo100-029/0000000343-001-EN
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Commissioning
5.21
Setting the opening stroke
Upon closing, a back suction effect is generated by the discharge system which prevents dripping on the plastic mixer outlet. The opening stroke and therefore also the
back suction effect of the valve can be set on the adjusting screw.
•
•
1
Plastic mixer
2
Spigot nut
3
Handle (option)
4
Non-return valve
5
Packing nut
6
Drive cylinder
7
Solenoid valve
8
Adjusting screw
9
Hexagon nut
A small opening stroke results in a small back suction effect.
A large opening stroke results in a large back suction effect.
1
2
3
4
5
6
7
8
9
The setting must be carried out with the valve closed.
Set the opening stroke to obtain the back suction of a minute quantity of material into the mixing tube tip at the end of a metering process.
The opening stroke is too small if the machine issues an error during the metering process due to overpressure.
 Hold the adjusting screw with an open-end wrench.
 Release the hexagon nut.
 Turn the adjusting screw clockwise to reduce the opening stroke.
• If the stop screw is screwed all the way to the stop, the valve will not be
able to open after starting!
 Turn the adjusting screw counterclockwise to increase the opening stroke.
 Hold the adjusting screw with an open-end wrench.
 Tighten the hexagon nut.
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Commissioning
5.22
Adjusting the gear metering pump
The pump sizes must be entered in the configuration menu. The values have already been checked and entered at the factory, if the machine has been run in with
the original material. This value must be checked and modified, if necessary, if the
machine was not run in with material or if the material has been changed.
Determining the pump
size
Note the following before starting:
•
•
•
•
•
•
•
•
Have a balance (precision of 1‰ of the measuring quantity) ready.
The empty weight of the measuring vessels must be known.
The exact density of the material must be known.
The material vessels must be filled.
The material must have been heated up.
The material must have been stirred.
The machine must have been de-aerated.
The flow rate should amount to 50% of the max. machine capacity
(5.14 Parameterization).
 Remove the end cap or mixer from the discharge system.
 Clean the outlet opening.
 Fit the adapter for volumetric measurement to the outlet opening.
 Press the
button on the left.
• Additional functions are displayed.
 Press the
button.
• Pre-selection for de-aeration with opened discharge system is active.
 Hold a collector vessel under the adapter for volumetric measurement.
 Press the
button.
• The adapter for volumetric measurement is filled.
 Release the
button or press the
or bubbles is discharged.
button as soon as material free of air
 Hold a weighed measuring vessel under the adapter for volumetric measurement.
 Press the
button.
• Material is discharged.
 For machines with speed check, press the
played pump speed.
button and write down the dis-
 For machines without speed check, the pump speed must be measured on the
coupling with a measuring instrument.
 After approx. 60 seconds, release the
button or press the
button.
If the desired time is entered in the "De-aeration" area under parameter "Metering time" during parameterization, material discharge ends automatically
after the time has expired.
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Commissioning
 Press the
ESC
button to deselect the function.
 Weigh the measuring vessel incl. material.
 Determine the net weight of the material (subtract empty weight) and write it
down.
 For the density of the material, see the batch record.
 Calculate the material volume based on the density.
 Calculate pump rotations based on time and speed.
 Calculate the pump size [cm³/rev] based on the volume and the pump rotations.
 Change the pump size value in the configuration menu (5.12 Configuration).
5.23
Adjusting the volume counter
The pulse values for volume counter A and volume counter B are contained in the
configuration. The values have already been checked and entered at the factory, if
the machine has been run in with the original material. This value must be checked
and modified, if necessary, if the machine was not run in with material or if the material has been changed.
Determining the volume
counter value
Note the following before starting:
•
•
•
•
•
•
•
•
Have a balance (precision of 1‰ of the measuring quantity) ready.
The empty weight of the measuring vessels must be known.
The exact density of the material must be known.
The vessels must be filled.
The material must have been heated up.
The material must have been stirred.
The machine must have been de-aerated.
The flow rate should amount to 50% of the max. machine capacity
(5.14 Parameterization).
 Remove the end cap or mixer from the discharge system.
 Clean the outlet opening.
 Fit the adapter for volumetric measurement to the outlet opening.
 Press the
button on the left.
• Additional functions are displayed.
 Press the
button.
• Pre-selection for de-aeration with opened discharge system is active.
 Hold a collector vessel under the adapter for volumetric measurement.
 Press the
button.
• The adapter for volumetric measurement is filled.
 Release the
button or press the
or bubbles is discharged.
button as soon as material free of air
 Press the
button.
• The diagnostics screen appears.
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Commissioning
 Press the
button.
 Press the
button for the corresponding volume counter.
• The counter readings are reset to zero.
 Press the
button.
• The system returns to the selected function.
 Hold a weighed measuring vessel under the adapter for volumetric measurement.
 Press the
button.
• Material is discharged.
 After approx. 30 seconds, release the
button or press the
button.
If the desired time is entered in the "De-aeration" area under parameter "Metering time" during parameterization, material discharge ends automatically
after the time has expired.
 Press the
ESC
button to deselect the function.
 Weigh the measuring vessel incl. material.
 Determine the net weight of the material (subtract empty weight) and write it
down.
 For the density of the material, see the batch record.
 Calculate the material volume based on the density.
 Press the
button.
• The diagnostics screen appears.
 Press the
button.
 Add up the displayed pulses from volume counters X1 and X2.
 Press the
key to return to the main menu.
 Divide the calculated volume by the sum of the pulses.
• The calculation gives a volume counter value X cm³/pulse.
Number value input
 Press the
button.
 If necessary, enter log-in data (5.13 User administration).
 Select parameter group "volume counter".
• The current pulse value ist displayed.
 Enter new pulse value.
 Press the
eldo100-029/0000000343-001-EN
key to return to the main menu.
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Commissioning
5.24
Check the mixing ratio
In order for the components to be discharged in the correct proportion, the mixing
ratio must be checked at regular intervals.
Note the following before starting:
•
•
•
•
•
•
Have a balance with a precision of 1‰ of the measuring volume ready.
The empty weight of the measuring vessels must be known.
The machine must have been filled.
The material must have been heated up.
The material must have been stirred.
The machine must have been de-aerated.
NOTICE
If the mixing helix drive is started while the adapter for volumetric measurement is screwed on, the dog hook will be ripped of and other parts will be damaged!
If an adapter for volumetric measurement is screwed to the static-dynamic mixer, the
mixing helix drive must not be started under any circumstances. Also, it is not permitted to carry out any function which automatically starts the drive.
► The adapter for volumetric measurement must only be screwed onto the discharge system in case of mixing ratio tests and functions within the function
check.
Measuring out the material
 Enter or modify the parameters required for mixing ratio control in the parameterization (5.14 Parameterization).
 Remove the end cap or the plastic mixer from the discharge system.
 Clean the outlet opening.
 Fit the adapter for volumetric measurement to the outlet opening.
 Hold a waste container under the adapter for volumetric measurement.
 Press the
button.
• The function has been preselected.
• A warning message appears.
 Confirm the warning message.
 Press the
button.
• The adapter for volumetric measurement is filled with material.
 Hold two weighed measuring vessels under the adapter for volumetric measurement.
 Press the
button.
• Parameterized material amount is discharged.
 Press the
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ESC
button to deselect the function.
eldo100-029/0000000343-001-EN
Commissioning
1
Adapter for volumetric
measurement
2
A component
3
B component
1
2
A
Calculating the mixing ratio
150
150
100
100
B
50
3
50
 Weigh the measuring vessel including the material.
 Determine the net weight of the material (subtract empty weight) and write it
down.
 Repeat the process three times and calculate the average values.
 See the density of A and B components on the batch records.
 Calculate the mixing ratio per volume parts.
1
Net weight of A component
2
Net weight of B component
3
Density of A component
4
Density of B component
5
Mixing ratio per volume
parts
Ending the check
2
5
B 67,27 g x 100
4
1,22 g/cm³
MV A:B = 100:
= 100 : 67,45
1
A 85,84 g
3
1,05 g/cm³
 Unscrew and clean the adapter for volumetric measurement.
 Flush the material discharge channels with material (6.9 Switch OFF), so they
are free from mixed material.
 Clean the mixer head with a cloth.
Calculate the mixing ratio
deviation
1
2
3
The mixing ratio deviation is calculated based on the nominal value and the calculated actual value of the corresponding parts of B component.
Actual value B component
part
Nominal value B component part
Mixing ratio deviation
eldo100-029/0000000343-001-EN
3
1
67,45 x 100
X=
2
66
-100
= +2,2%
5/73
Commissioning
5.25
Correcting the mixing ratio
The mixing ratio is determined by the flow rate of the respective component. The
flow rate adjustment values must be determined for the different machine capacities.
They can be saved in the
In the
menu under "General settings", you can determine whether the correc-
tion values of the
Machine with mixing ratio
control
menu or in a metering program.
menu or those of the metering program shall be used.
The flow rate correction values can be determined automatically.
 At "General settings" in the configuration menu, select whether the value is to be
determined for an individual or for all sections of the machine.
 Remove the end cap or mixer from the discharge system.
 Hold a collector vessel under the discharge system.
 Press the A button.
• The function for the automatic determination of the flow rate correction
values is pre-selected.
 Press the
button.
• Material is discharged at an individual or all machine lines.
• The system calculates and stores the flow rate correction values.
 Select the
menu.
 For "Flow rate adjustment", press the
• The values are interpolated.
Systems with mixing ratio
regulation
Since the system controls the flow rates of the individual components, flow rate correction values are not required. However, in special cases the correction values can
be entered in the
74/5
button.
menu.
eldo100-029/0000000343-001-EN
Commissioning
5.26
Decommissioning
If the system needs to be shut down for a long period of time, several safety measures must be taken.
NOTICE
When processing PU systems, pay special attention to the isocyanate. This is
an hygroscopic product.
The component tries to absorb humidity. This leads to reactions and causes crystallization in the liquid. These crystals are often the cause for metering errors, clogging
or poor reaction of the two components.
NOTICE
When processing materials containing fillers or pigments, keep in mind that
fillers settle and cause clogging or blockage (especially in volume counters).
If any of the components being processed in the machine reacts with humidity or
contain fillers, the material-carrying parts must be flushed with a cleaning agent. If
necessary, information on which components are the components concerned are to
be obtained from the material manufacturer. Never fill the system with explosive liquids containing solvents if you are not authorized to do so. Such materials can cause
an explosion.
Decommissioning
Depending on the configuration of the system, the following additional measures
must be taken.
 Move the pump elevator to the lowest possible position.
 Retract the pistons of metering and delivery pumps completely.
 Refill the sealing systems with sealing liquid.
 Clean the external surfaces of the machine.
 Provide protection against dust and humidity.
 Isolate the machine from mains supply.
 If possible, do not remove compressed-air connections. Material-carrying parts
must be hermetically sealed.
 Replace and regenerate silica gel.
 Note the temperature range for interim storage (4.6.3 Ambient conditions).
NOTICE
► Pay attention to the permissible storage periods and storage temperatures of all
materials remaining in the system.
If you are planning to decommission the machine for a long period of time,
please contact our service department. For further information, please contact
your local DOPAG Service www.dopag.com.
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Commissioning
76/5
eldo100-029/0000000343-001-EN
Operation
6
Operation
6.1
Setup
Prior to starting production, the machine must be prepared for operation.
The machine must be inspected visually every day before the beginning of the
work shift. It should be shut down immediately, if there is any doubt about
trouble-free operation. Before starting further operations, the machine must
be checked by the maintenance staff.
Note the following before starting:
•
•
•
Operation of the machine must be started correctly.
The system must have been filled.
The system must have been de-aerated.
NOTICE
If the machine has been at a standstill for a long time, material could settle and
produce sediments or material could crystallize or harden.
This could cause damage when the machine is put again into operation.
► Please contact the Service before switching on the machine after a long standstill period.
Switching on the system
 Turn on the main switch.
 Open the compressed-air main valve on the compressed-air maintenance unit.
 Acknowledge error messages (4.3.10 Messages).
Setting up the material
vessel
 Open the air shut-off valve.
 Check and, if necessary, adjust the vessel pressure.
 Open the vessel outlet shut-off valve.
Switching on the agitator
 Press the
button.
• All agitators are switched on.
Agitators can be switched on individually:
 Press the
button on the right.
 Press the
button for the relevant component.
• The agitator runs in the parameterized interval mode.
 Press the
Starting recirculation
button to close the window.
 Open all recirculation shut-off valves (in case of manual function).
 Press the
button.
 Press the
button.
• All components are circulated in the circuit in the parameterized interval
mode.
Circuits can be switched on individually:
eldo100-029/0000000343-001-EN
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Operation
 Open the recirculation shut-off valve (in case of manual function).
 Press the
button on the left.
 Press the
button for the relevant component.
 Press the
button.
• Recirculation is operated in the parameterized interval mode.
 Press the
button to close the window.
Recirculation should be active for a few minutes.
Turning off recirculation
 Press the
 Press the
button.
ESC
button to deselect the function.
 Close the recirculation shut-off valve (in case of manual function).
Check the mixing ratio
Prior to starting production, check the mixing ratio (5.24 Check the mixing ratio).
Executing pre-run
 Screw a new plastic mixer onto the discharge system.
 Position the outlet system over a waste container.
 Press the
button.
• Preselection is active.
 Press the
button.
• The plastic mixer is filled with mixed material.
• After the pre-run has successfully been executed, the metering functions
are enabled for selection.
6.2
Metering
 Position the discharge system on the component.
One of three different metering functions can be selected.
Continuous metering
 Press the
button.
• Preselection is active.
• Process data is displayed.
 Touch the value in the dark gray field for the flow rate in order to make changes
if this is required.
• An input window is opened.
 Enter the new value and confirm it.
 Press the
button.
• Material is discharged.
 Release the
button or press the
button.
• The material discharge process is terminated.
78/6
eldo100-029/0000000343-001-EN
Operation
The running metering process cannot be interrupted until the quantity entered
in parameter "Min. metering quantity with cont. metering" (
al settings") has been discharged.
 Press the
the function.
button to discharge material again or the
ESC
menu, "Gener-
button to deselect
Programmed metering
If the program No. is entered under "Metering program" in the parameterization menu
, this program is also selected for the metering function.
 Press the
button.
• Preselection is active.
• The current program number is displayed.
 Touch the program number in the dark gray field to change it.
• An input window is opened.
 Enter a new program number.
 Press the
button.
• Material is discharged.
• The metering stops when the target quantity is reached.
 Press the
button to interrupt the ongoing metering.
• The material discharge process is terminated.
 Press the
the function.
Shotwise metering
button to discharge material again or the
ESC
button to deselect
 Press the
button.
• Preselection is active.
• Process data is displayed.
 Touch the value in the dark gray field for flow rate or target quantity in order to
make changes.
• An input window is opened.
 Enter the new value and confirm it.
 Press the
button.
• Material is discharged.
• The metering stops when the target quantity is reached.
 Press the
button to interrupt the ongoing metering.
• The material discharge process is terminated.
 Press the
the function.
eldo100-029/0000000343-001-EN
button to discharge material again or the
ESC
button to deselect
6/79
Operation
6.3
Changing setpoint values
Setpoint values and actual values are shown on the operating screen. The setpoint
values can be changed here without switching over to the
menu. The changeable setpoint values have a number field wirh dark gray background.
 Touch the setpoint value.
• The keypad appears.
 Enter new setpoint value.
 Confirm the input.
• The new setpoint value is applied and saved in the
6.4
menu.
Activate the operating data recording
If the operating data are to be saved, note the following:
 Insert a USB stick into the USB port.
 Select the
menu.
 Select the parameter "General settings".
 Set the "Operating data recording" parameter to "ON".
 In the main menu, press the
button.
• The button is displayed in green.
• After metering has been finished, the file "DAQ.csv" is created on the USB
stick.
• Any operating data acquired are stored in this file in the parameterized cycle.
 If the parameter "Operating data recording" is set to "ON" and no USB stick has
been inserted, an error message is issued as soon as a function is selected.
Remove the USB stick
 In the operating screen, press the
button.
• The button is displayed in gray.
• The USB port is disabled.
 Remove the USB stick.
80/6
eldo100-029/0000000343-001-EN
Operation
6.5
Interface flow diagram
The diagrams show the signal sequence for shotwise metering.
Shotwise metering/regeneration
ready to 1
be metered 0
metering running 1
0
alarm 1
0
potlife error 1
0
start 1
0
closed
stop 1
0
regeneration 1
position reached 0
T2.3
T2.1
T1 T2.1
T5.3
T5.2
T3 T4 T5.1
T6
T8.2
T7 T8.1
T9 T10
T11
T12.2
T12.1
T13 T14
Legend
T1
Pre-run mode selected on the touch screen
T2.1
Start signal set: Pre-run is started.
T2.2
Metering in progress
T2.3
Start signal reset
T3
Pre-run completed
T4
Shotwise metering mode selected on the touch screen
T5.1
Start signal set: Metering shot started
T5.2
Metering in progress
T5.3
Start signal reset
T6
Metering shot completed
T7
Potlife expired
T8.1
Regeneration position reached, regeneration control time not expired!
T8.2
Regeneration in progress
T9
Mixture volume metered out, regeneration completed
T10
Regeneration position is abandoned again
T11
Fault e.g. pressure sensor (shotwise mode is deselected automatically)
T12.1 Alarm on the touch screen acknowledged, fault not removed, metering start
remains locked
T12.2 Alarm reset
T13
Fault (e.g. pressure sensor) removed
T14
Shotwise metering mode selected on the touch screen
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Operation
Shotwise metering/stop reset before acknowledgement of the alarm
ready to 1
be metered 0
metering running 1
0
alarm 1
0
potlife error 1
0
start 1
0
stop 1
0
regeneration 1
position reached 0
T2.3
T2.2
T1 T2.1
T3.2
T3.1 T4
T5.2
T5.1
Legend
82/6
T1
Shotwise metering mode selected on the touch screen
T2.1
Start signal set: Metering shot started
T2.2
Metering in progress
T2.3
Start signal reset
T3.1
Stop signal set, metering shot stopped
T3.2
Metering not in progress, alarm
T4
Stop signal reset
T5.1
Alarm on the touch screen acknowledged, fault not removed, metering start
remains locked
T5.2
Alarm reset: Metering remains selected
eldo100-029/0000000343-001-EN
Operation
Shotwise metering/stop reset after acknowledgement of the alarm
ready to 1
be metered 0
metering running 1
0
alarm 1
0
potlife error 1
0
start 1
0
stop 1
0
regeneration 1
position reached 0
T2.3
T2.2
T1 T2.1
T3.2
T4.2
T3.1
T4.1
T5
Legend
T1
Shotwise metering mode selected on the touch screen
T2.1
Start signal set: Metering shot started
T2.2
Metering in progress
T2.3
Start signal reset
T3.1
Stop signal set, metering shot stopped
T3.2
Metering not in progress, alarm
T4.1
Alarm on the touch screen acknowledged, fault not removed, metering start
remains locked
T4.2
Alarm reset: Metering deselected
T5
Stop signal reset
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Operation
6.6
Refilling the material vessel
In case of a shortage of material, the material vessels must be refilled.
WARNING
Hazard caused by spattering material!
When being filled in, material can spatter and cause eye injuries and skin lesion.
► Wear eye protection and protective gloves.
NOTICE
The material components must not be confused under any circumstances.
Mixing of material inside the vessel may lead to substantial damage.
► Make sure that the vessel is filled with the correct component.
Filling into an open material vessel
6.7
The vessel cover is removed and the material is filled into the open vessel. Observe
the procedures described in (5.16 Filling (material vessel)).
Request material consumption
Using this function, it is possible to check the material consumption. This value can
be reset to 0.
Request material consumption
 Press the
button.
 Press the
button repeatedly.
• The material consumption is displayed.
Reset material consumption
84/6
 Press the
button for the appropriate component to reset the value to zero.
 Press the
button to exit the menu.
eldo100-029/0000000343-001-EN
Operation
6.8
Relieving pressure from discharge system
If the machine activates an error due to overpressure, pressure must be discharged.
Pressure must also be discharged before the machine is switched off. When pressure is discharged, small amounts of material escape from the discharge system.
Discharge pressure
 Place a collector vessel under the discharge system.
 Press the
button.
• The function is selected.
• A warning message appears.
 Read and confirm warning message.
 Press the
button.
• The discharge system opens and material flows.
 Release the
button when the pressure has been equalized.
 Press the ESC button.
• The function is terminated.
In case of discharge systems with separate valves, the pressure can be discharged
at one individual component:
 Press the
button on the left.
• Additional functions are displayed.
 Press the
button for the relevant component.
• The function is selected.
• A warning message appears.
 Read and confirm warning message.
 Press the
button.
• The discharge system opens and material flows.
 Release the
button when the pressure has been equalized.
 Press the ESC button.
• The function is terminated.
6.9
Switch OFF
The system must be switched off after work.
Remove the plastic mixer
 Completely loosen the spigot nut.
 Pull out the plastic mixer.
 Clean the plastic mixer or allow the material to harden.
eldo100-029/0000000343-001-EN
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Operation
Flushing the discharge
system
NOTICE
After work, residues of the mixed material may remain in the discharge channels.
If such material hardens, the channels will clog.
► The discharge channels of the outlet system must be flushed thoroughly after
work.
 Hold a collector vessel under the discharge system.
 Press the
button.
• Additional functions are displayed.
 Press the
button.
• Pre-selection for de-aeration with opened discharge system is active.
• Process data is displayed.
 If required, touch the value in the dark gray field to change it.
• The input window appears.
 Enter the new value and confirm it.
 Place a collector vessel under the discharge system.
 Press the
button.
• Material is discharged.
 After approx. 3 seconds, release the
 Press the
ESC
button or press the
button.
button to deselect the function.
 Clean the mixer head with a cloth.
 Repeat the process for the second component.
• The material discharge channels are free from mixed material.
Relieving pressure from
discharge system
See (6.8 Relieving pressure from discharge system).
Closing the discharge
system
 Clean the material discharge channels at the exhaust with a cloth.
Discharging pressure
from material vessel
 Close the air shut-off valve on the vessel.
 Fit a heavily greased end cap to the discharge opening and hand-tighten the
spigot nut.
 Open the de-aeration valve on the vessel.
• Compressed air escapes.
 Close the de-aeration valve when the vessel has been depressurized.
Discharging the material
pressure
 Hold a collector vessel underneath the de-aeration valves.
 Open the de-aeration valves.
• Material flows until the pressure is equalized.
 Close the de-aeration valves.
 After having been operated, de-aeration valves with blocking attachment must
be flushed (5.20 Flush the de-aeration valve).
86/6
eldo100-029/0000000343-001-EN
Operation
Switching off the system
 Close the main compressed-air valve.
 Turn off the main switch.
 Clean the machine (7.2.3 Cleaning).
6.10
Faults
You will be notified of alarm messages, fault messages and information by means
of a pop-up window (4.3.10 Messages) and an alarm sound. In most cases, they can
be acknowledged, but have to be repaired. The Status menu (4.3.9 Status) will then
display a possible error cause.
Overdosage
Causes
Remedies
Too much material discharged.
 Check the overflow tolerance in the
metering program.
 Check the parameter values in case
of delay times.
 Decrease the opening stroke at the
dispensing valve if necessary.
 Check whether the machine has
been de-aerated.
 Check the dispensing valve for fast
closing. Do not overtighten the adjustable seals.
Underdosage
Causes
Remedies
Insufficient material discharged.
 Check the parameter values in case
of delay times.
Causes
Remedies
Metering time error
Shotwise metering operating mode: Per-  Check the dispensing valve.
mitted metering time was exceeded.
 Check the parameters in the metering program.
 Check volume counters.
 Check metering pumps.
 Check the material supply.
Mixing ratio
Causes
Remedies
Air in system.
 Reset the error message (Reset).
 De-aerate.
 Refill the mixer (pre-run).
Lines blocked (clogged).
 Discharge pressure.
 Remove blockage.
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Operation
Causes
Remedies
Leakage in system.
 Check system for leakage (visual
check).
Faulty metering pump.
 Seat leaking or gear broken.
 Overhaul metering pump.
Faulty sensor.
 Replace sensor.
Possible cause
Remedy
No signal from the pressure sensor.
 Check the wiring using the circuit diagram (11 Circuit diagrams).
Faulty sensor.
 Check/replace sensor.
Cable on sensor faulty.
 Check/replace cable.
Connector on sensor faulty.
 Check/replace connector.
Causes
Remedies
Leakage in system.
 Check system for leakage (visual
check).
Metering pump does not pressurize.
 Check drive pressure.
Pressure sensor fault
Pressure too low
 Broken piston or gear.
 Material vessel or container is empty.
Pressure sensor misadjusted.
 Check pressure sensor settings.
Causes
Remedies
Mixer hardened.
 Discharge pressure.
Pressure too high
 Replace.
Dispensing/metering valve does not
open.
 Discharge pressure
 Check pneumatic valve for sticking.
 Clean the valves.
Pressure sensor misadjusted.
 Discharge pressure.
 Check pressure sensor settings.
Too high flow rate or too high viscosity.
 Reduce the flow rate.
Causes
Remedies
Wrong parameter setting.
 Check parameters for drive regulator.
Faulty drive regulator.
 Check/replace drive regulator.
Error message for drive regulator.
 Switch system off/on.
Faulty cable.
 Check/replace cable.
Drive regulator error
88/6
eldo100-029/0000000343-001-EN
Operation
Channel difference on
volume counter
Causes
Remedies
Metering pump drive locked.
 Discharge pressure, check metering
pump for blockage.
Causes
Remedies
Different number of sensor pulses from
volume counter.
Check the wiring using the circuit diagram (11 Circuit diagrams).
Faulty cable on volume counter.
Check cable and plug-in connection.
Faulty sensor in volume counter.
Replace volume counter.
Causes
Remedies
Volume counter sends pulses during
metering pauses.
 Check the discharge system for
closing.
Leakage
 Check shut-off and check valves of
the metering pump.
Material delivering system parts are
leaking.
 Check system parts for leaks.
Causes
Remedies
Agitator blocked.
 Check for mechanical obstruction.
Agitator fault
 Reset motor protection switch.
Agitator is faulty.
 Replace the agitator.
Motor protection switch was triggered.
 Reset motor protection switch.
 Replace the agitator.
The contactor does not switch.
 Check contactor.
Connector of motor cable not plugged in.  Connect the connector.
Metering process
stopped
Causes
Remedies
Stop button is pressed during metering.  Press the Start button.
Faulty sensor.
 Check/replace sensor.
Faulty cable.
 Check/replace cable.
Causes
Remedies
Regeneration stopped
Stop button is pressed during regenera-  Replace mixer.
tion.
Faulty sensor.
 Check/replace sensor.
Faulty cable.
 Check/replace cable.
eldo100-029/0000000343-001-EN
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Operation
Outlet not in regeneration
position
Causes
Remedies
Regeneration position has not been ap-  Check traveling system.
proached.
 Replace mixer.
Metering program does
not contain data
Flow rate profile does not
contain data
Delivery capacity outside
the tolerance range
Faulty sensor.
 Check/replace sensor.
Faulty cable.
 Check/replace cable.
Faulty regeneration position signal by
customer.
 Check customer signal.
Causes
Remedies
Missing values.
 Complement values in parameter
setting.
Causes
Remedies
Missing values.
 Complement values in parameter
setting.
Causes
Remedies
Metering pump does not work correctly.  Check parameter setting for metering pumps.
 Check speed initiator.
 Check volume counters.
Speed initiator does not work correctly.
 Check metering pump.
 Check speed initiator.
 Check volume counters.
Volume counter does not work correctly.  Check metering pump for wear or replace it if necessary.
 Check speed initiator.
 Check volume counters.
Potlife expired
Start without metering
program data
90/6
Causes
Remedies
Process-related waiting times or negligence.
 Discharge material immediately, replace or flush mixer.
Causes
Remedies
Missing values.
 Complement values in parameter
setting.
eldo100-029/0000000343-001-EN
Operation
Mixer fault
Causes
Remedies
Mixing helix monitoring does not provide  Check sensor.
pulses.
Faulty mixer drive regulator
No signals from volume
counters.
Mixing helix does not have magnets.
 Check/replace mixing helix.
Faulty mixing helix.
 Check/replace mixing helix.
Faulty sensor for mixing helix monitoring.
 Check/replace mixing helix.
Causes
Remedies
Wrong parameter setting.
 Check parameters for drive regulator.
Faulty drive regulator.
 Check/replace drive regulator.
Error message for drive regulator.
 Switch system off/on.
Faulty cable.
 Check/replace cable.
Causes
Remedies
Faulty sensor.
 Check both sensors, replace volume
counter if necessary.
Faulty cable.
 Check the wiring referring to the circuit diagram (11 Circuit diagrams).
Volume counter blocked.
 Remove and flush volume counter.
Metering pump does not work.
 Check/replace metering pump.
No material flow, lines blocked/clogged.  Discharge pressure, remove blockage/clogging.
Filling fault
Possible cause
Remedy
Maximum filling time has been exceed-  Check value for filling time in the paed.
rameterization.
 Check the shut-off valve for proper
operation.
 Check the filling level of the material
supply.
 Check the delivery capacity of the
material supply.
Faulty temperature sensor of heating unit
Causes
Remedies
Faulty sensor.
 Check the wiring referring to the circuit diagram (11 Circuit diagrams),
replace sensor if necessary.
Cable on sensor faulty.
 Replace cable.
Connector on sensor faulty.
 Replace connector.
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Operation
Temperature too high/too
low
Causes
Remedies
Temperature limit parameters incorrectly  Check parameter setting.
set.
Safety shutdown of the
heating device
Temperature too high
Outlet not in flush position
Faulty sensor.
 Check/replace sensor.
Faulty heating unit.
 Check/replace heating unit.
Causes
Remedies
Wrong parameter setting.
 Change the value for safety shutdown in the configuration menu.
Faulty sensor.
 Check/replace sensor.
Faulty heating unit.
 Check/replace heating unit.
Causes
Remedies
Position has not been approached.
 Replace mixer.
Faulty sensor.
 Check/replace sensor.
Faulty cable.
 Check/replace cable.
Faulty signal by customer.
 Check customer signal.
Causes
Remedies
Stop button has been pressed during
flushing.
 Press the Start button.
Faulty sensor.
 Check/replace sensor.
Faulty cable.
 Check/replace cable.
Faulty signal by customer.
 Check customer signal.
Causes
Remedies
Vacuum pump blocked.
 Check for mechanical obstruction.
Flushing stopped
Faulty vacuum pump
 Reset motor protection switch.
Faulty vacuum pump.
 Replace the vacuum pump.
Motor protection switch was triggered.
 Reset motor protection switch.
 Replace the vacuum pump.
The contactor does not switch.
 Check contactor.
Connector of motor cable not plugged in.  Connect the connector.
External stop active/
Emergency stop active
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Possible cause
Remedy
Emergency stop was initiated (external
signal).
 Reset signal.
Emergency stop button was pressed.
 Release emergency stop button.
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Operation
Possible cause
Remedy
Broken wire in jumper for the emergency  Replace wire.
stop.
Machine data error, default values taken over
Causes
Remedies
If the "Machine data" data structure (da-  Press Reset button (default values
ta module) changes in the program, all
will be loaded).
values are initialized with default values.
Flash Eprom fault: Sectors cannot be deleted!
Causes
Remedies
Error when writing on the internal mem-  Press Reset button (default values
ory.
will be loaded).
Initialization error of the
CAN-Open module
Causes
Remedies
Fault of expansion module.
 Check/replace the input cable of the
CAN-Open module.
 Check/replace the input connector
of the CAN-Open module.
Causes
Remedies
Faulty USB data medium
In parameter setting, "Save" or "Re Connect a USB stick to the USB port
store" was selected in the data adminisof the MR control unit.
tration menu before connecting a USB
stick.
Buffer battery
Causes
Remedies
Battery is almost empty.
 Replace the battery (7.8 Buffer battery).
Causes
Remedies
Error is unknown.
 Please contact the Service.
Unknown error
6.11
Troubleshooting
This list gives information on possible system faults and how they can be solved.
The system does not deliver any material upon
start
Causes
Remedies
Compressed air main valve closed.
Open the compressed-air main valve.
Material vessel empty.
Refill material.
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Operation
Causes
Remedies
Close shut-off valves at outlet of material Open the shut-off valves.
vessels.
Mixed material hardens
incompletely
Causes
Remedies
Valves to not open.
Check the compressed air supply.
Leakage in system.
Remove the leakage.
Recirculation shut-off valve leaking.
Wear signs on the metering pumps and/ Overhaul the metering pumps and/or
or the mixing system.
mixing system.
Parameterization of the volume counter Check the parameter settings.
incorrect.
Entrapped air in the
mixed material
Metering pump makes
noises
Material drains off the
sealing system
Shut-off valve for manual recirculation
open.
Close the shut-off valve.
Causes
Remedies
Material vessel empty.
Refill material.
System incorrectly de-aerated.
De-aerate the system.
Causes
Remedies
Material supply not guaranteed.
Check the material supply.
Faulty metering pump.
Overhaul the pump.
Causes
Remedies
Faulty seal of the metering pump.
Replace sealing system.
Replace seals if necessary.
Sealing liquid container
flowing over
Causes
Remedies
Faulty seal of the metering pump.
Replace the sealing system.
Replace the seals if necessary.
Mixing system drips
Causes
Remedies
Mixing tube does not seal against mixing Clean the mixing block and tighten the
block.
mixing tube with the spigot nut.
Back suction effect insufficient.
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Set the back suction effect on the discharge system.
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Operation
6.12
Reset of agitator motor starter
After an overload state has been triggered by the agitator motor, the starter must be
reset.
1
Device LED
2
Failure LED
3
State LED
4
Reset Mode LED
5
Reset pushbutton
1
2
3
4
5
Fig. 6-1 Starter
LED status display
Agitator OFF - no fault
Agitator ON - no fault
Device
Failure
State
Reset
Device
Failure
State
Reset
green
off
off
off
green
off
green
off
DANGER
Danger of electric shock!
Touching parts in this danger zone may result in serious or fatal injury from electric
shock.
► Work on power supply systems may only be performed by qualified electricians.
Reset in case of triggered
overload state
 Open the control cabinet.
 Wait until the three-minute cooling time has expired.
 Press the reset pushbutton.
• The agitator motor restarts.
 Close the control cabinet.
In case the overload state is triggered once again, observe the operating instructions
of the starter (see chapter Accompanying documentation).
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Operation
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Maintenance
7
Maintenance
7.1
General
Maintenance work must be undertaken by properly trained maintenance staff
(2.3 Target audience).
DANGER
Danger arising from maintenance work!
If you undertake maintenance work without having received the necessary training,
system safety is no longer guaranteed. This can cause serious physical injury or
death.
► Observe all safety instructions and leave maintenance to trained staff.
WARNING
Danger from high pressure!
When carrying out maintenance work on systems that have not been switched off or
depressurized, there is danger of serious injuries due to material spurting out or
ejection of components under pressure.
► Carry out the maintenance work only on systems that have been switched off
and disconnected from the compressed air supply. Discharge the material pressure in the system before carrying out maintenance work. No residual pressure
may exist.
7.1.1
Service
Please note the Service Center responsible for your area. For current addresses, go
to www.dopag.com.
7.1.2
Maintenance contract
A maintenance contract can be made in order to preserve the operating ability of the
machine. Production downtimes can be prevented by having maintenance work,
e.g. replacement of filters and seals, leak tightness tests and functional checks and
checking the system parameters, carried out by our service department on a regular
basis.
7.1.3
DOPAG spare parts
DOPAG Spare parts can be found in the 10 Parts lists. For further information, see
the spare parts drawing.
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Maintenance
WARNING
It is dangerous to use incorrect spare parts!
Using spare parts that have not been tested and approved by DOPAG means that
system safety is not guaranteed. This can cause serious physical injury or death.
► Use DOPAG spare parts only.
For DOPAG Customer Service being able to deal with your order, please give the
following order details:
Order details
Example
Machine number / serial number
1002010-1
Item number
1006010
Designation
Seal set
Number of items
1
Storing the most important spare parts and parts subject to wear on the installation site is an important prerequisite for continuous operation and operational readiness of the machine or of the module supplied. If you have any
question concerning the recommended spare parts, please contact DOPAG
Service, www.dopag.com.
7.1.4
Operating materials and lubricants
DOPAG recommends the following operating materials and lubricants depending on
the machine version. See the data sheets on the operating materials and lubricants
used in chapter 13, Accompanying documentation.
Sealing liquid
Medium
Item no.
Designation
Quantity
Sealing liquid
22005230
DINP
5 kg
For filling the seal chambers, lubrication cups on stuffing box nuts or sealing liquid
containers, it is recommended to use the sealing liquid DINP.
Sealing fluid
Medium
Item no.
Designation
Quantity
Mesamoll sealing grease
22023865
Sealing grease 1 can
0.5 kg
For filling or flushing seal chambers or de-aeration valves with blocking attachment
or for filling the sealing cap for the discharge system, it is recommended to use Mesamoll grease as a sealing fluid.
Petroleum jelly
Medium
Item no.
Designation
Quantity
Petroleum jelly
90.02.004
Petroleum jelly grease
0,5 kg
To lubricate O-rings, casings or threads, it is recommended to use commercially
available petroleum jelly.
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Maintenance
Desiccant
Medium
Item no.
Designation
Quantity
Desiccant
22026975
Silica gel filling
1.5 kg
For filling the silicagel air dehumidifier.
7.1.5
Adjustable seals
During the first week of operation, adjustable seals must be tightened continuously
until they are correctly run-in. Finally, the seals must be adjusted weekly. A few drops
of oil or sealing fluid added to the seal chamber will prolong the seal's service life.
Seal leakage can be reduced by tightening the adjusting nuts, however, it cannot be
reduced entirely. If after adjustment the leakage is still excessive, the seal must be
replaced.
Retighten the seals only when the system is de-pressurized!
1
Piston rod
2
Adjusting nut
3
Seal packing
4
Seal holder
5
Pressure ring
6
V sleeve
7
Shaft
8
Hole for tightening
1
8
2
3
1
7
8
8
2
2
5
5
6
4
Adjusting
3
4
 The seal must be tightened with the adjusting nuts.
 Insert an appropriate tool (e.g. a punch) into the hole for tightening.
 For the larger seals (e.g. on metering pumps), use two tools in order to apply
more force.
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Maintenance
1
Punch
2
Special tool
2
1
A certain un-tightness is allowable by design without the need to change the
seals Should seal leakage occur, even tightening will not achieve 100% tightness neither. Exercise care as overtightening can adversely affect functional
operation.
7.2
Maintenance of the modules
7.2.1
Maintenance schedule
To ensure trouble-free operation, the following maintenance intervals must be observed for various components:
DOPAG recommends to have an annual maintenance carried out by an inhouse specialist. Individual training for your staff is offered. For further information, please refer to www.dopag.com.
100/7
Maintenance task
Interval
Visual inspection
daily
Cleaning
daily
Material lines
weekly
Compressed-air maintenance unit
weekly
Silica gel air dehumidifier
adapt according to operation
Checking the material
monthly/adapt according to operation
Material filter
weekly
Gear pump
daily/quarterly
Discharge system
weekly
Diaphragm vacuum pump
daily
Liquid separator
daily
Touch-screen
if required
Mixing ratio (5.24 Check the mixing ratio)
adapt according to operation
Save data (7.7 Data storage)
monthly
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Maintenance
7.2.2
Visual inspection
The following points must be checked:
•
•
•
•
•
•
•
•
Are all safety systems present and fully functional?
Are the complete system operating instructions available?
Are all safety and danger warnings as well as signs present and clearly legible?
Are all the connecting couplings tight?
Is the main switch (circuit breaker) freely accessible?
Does the system shut down immediately when the main switch is actuated?
Are cable connections tight and undamaged?
Is the control/switch cabinet locked and the key secured against unauthorized
use?
Are the vent holes on the control/switch cabinet, the heating fan, and the motors
free from dust?
•
7.2.3
Cleaning
The system should be cleaned daily and immediately if it is contaminated with material. Dried material is very difficult to remove and requires a great effort. Observe
the cleaning operation safety information (see chapter 3.7 Flushing and cleaning the
system).
 Switch off the entire system. Proceed according to the instructions in chapter
6.9 Switch OFF.
Switching off
Pressure discharge
 Position collector vessel below the venting unit.
 Open the venting unit.
• Material will flow until the pressure has been equalized.
 Close the venting unit.
 Remove excess material.
Cleaning the system
NOTICE
Wrong cleaning agent for cleaning the system.
Under no circumstances must the system be sprayed with water.
► Determine which cleaning agent to use from the material used, and clean the
system as environmentally friendly and with as much care as possible.
 Close the main compressed-air valve.
 Rub the system down with a cloth.
7.2.4
Checking lines
Material lines
The lines and connections must be checked for damage. If a leak occurs, determine
whether or not a component is defective or a connection must be re-sealed. Replace
defective parts immediately!
If the lines and connections are split, crushed or there are other damages,
they must be replaced. After replacement, the system must be depressurized.
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Maintenance
Replacement of lines
The lines must be replaced at appropriate intervals.
Lines requirements
Recommended replacement intervals
normal requirements
every 6 years (incl. max. 2-year storage)
higher requirements (e.g. multiple shift after a 2-year operating time
operation, major external impacts, or internal impacts from the medium)
7.2.5
Compressed-air maintenance unit
The quality of the compressed air, which drives the machine, depends on the maintenance.
1
Compressed-air connection
2
Main valve for compressed air
3
Compressed-air regulator
4
Distributor
5
Pressure gauge
6
Filter with water separator
7
Drain plug
8
Fine filter with water separator
9
Silica gel air dehumidifier
1
3
2
4
10 Unlocking device
5
Drain water
6
7
9 10
8
The filter must be drained frequently. If there is too much water in the water separator, it can adversely affect the equipment and its function.
 Open the compressed-air main valve.
 Hold collector vessel under the filter housing.
 Open the drain plug by turning it to the left by several turns.
• Water drains off.
WARNING
Risk of splashing!
The water is released under pressure and spraying can occur.
► Wear safety goggles.
 When all water has drained off, close the drain plug by turning it to the right.
Clean air filter and water
separator.
Air filter and water separator are to be inspected weekly for contamination and
cleaned when necessary.
 Close the main compressed-air valve.
 Check whether pressure has been discharged from the material vessel. If necessary, de-aerate using the de-aeration valve of the material vessel.
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Maintenance
NOTICE
Cleaning the filter housing.
Using chemicals could destroy the transparent filter holders.
► Clean the air filter and filter holder with water only!
 Pull down the unlocking device.
 Turn the filter holder to the left by 1/4 turn and then remove it by pulling it downwards.
 Clean filter housing and filter with water.
 Attach the filter holder and turn it to the right until it is locked.
 Open the compressed-air main valve.
7.2.6
Silica gel air dehumidifier
The silica gel air dehumidifier removes moisture from the flowing compressed air.
The dehumidifier prevents too moist compressed-air being fed into the material vessel. The silica gel can be regenerated by drying. Silica gel when saturated with moisture changes color. This is visible from the outside by looking through the
transparent vessel.
Unsaturated silica gel contains orange and white granulate.
Saturated silica gel is completely white.
1
Air dehumidifier
2
Vessel
1
2
WARNING
Granulate material could be projected!
If the system is still under pressure, granulate material could be thrown into your
eyes when removing the sight glass.
► Make sure that there is no air pressure in the system. Wear eye protection!
Exchange silica gel
 Discharge compressed air pressure.
 Remove the vessel downwards by turning it to the left.
 Fill two thirds of the vessel with new or regenerated silica gel.
 Screw on the vessel and tighten it by hand.
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Maintenance
 For regeneration, heat the silica gel for approx. 1 hour with hot, dry air at 120 °C
maximum.
 After cooling in dry air, the silica gel can be reused.
The frequency with which the silica gel must be regenerated depends on the
quality of the compressed air and on the throughput. This interval must be
specified by the user according to his own requirements, conditions and observations.
7.2.7
Checking the material
With materials sensitive to humidity or reactive materials, skin may form on the material surface. If this skin or parts of it reach the outlet of the vessel or even the metering pump, problems or damage may occur.
The material in the material vessel must be inspected every month and strained f
necessary. The inspection interval can be adjusted based on the inspection result.
NOTICE
When processing PU systems, pay special attention to the isocyanate. This is
an hygroscopic product.
The component tries to absorb humidity. This leads to reactions and causes crystallization in the liquid. These crystals are often the cause for metering errors which
then lead to a poor reaction of the two components. The crystals can also clog the
material filter.
► Therefore, remove any visible contamination on the material vessels.
WARNING
Hazard caused by abrupt starting of agitator!
When getting near rotating agitator vanes with the limbs, there is hazard of serious
injuries such as fracture, contusion or skin injury.
► Before opening the material vessel, the power connector must be disconnected
from the agitator motor.
 Turn off the main switch.
 If required, disconnect the power supply connector from the agitator motor.
 If required, disconnect the level probe or pressure sensor connector.
 Close the air shut-off valve of the vessel fitting.
 Open the air outlet valve.
• Air escapes.
 Close the air outlet valve when the pressure has equalized.
 Loosen the star knob bolts on the vessel lid manually.
 Remove the lid.
 Check the material.
 Use a strainer to remove any contaminants or a skin from the material surface.
For example, a kitchen strainer can be used.
 Clean vessel rim, seal and lid.
 Lubricate the seal (silicone oil or petroleum jelly).
 Fit the lid.
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Maintenance
 Hand tighten the star knob bolts.
 If required, reconnect the power supply connector to the agitator motor.
 If required, reconnect the level probe or pressure sensor connector.
 Open the air shut-off valve of the vessel fitting.
 Turn on the main switch.
7.2.8
Material filter
The material filters must be regularly maintained. Disassemble and clean the filter
element.
NOTICE
Contaminated material filters cause faulty operation of the system!
Particles clog the filter. Depending on the material, the filter must be cleaned more
often.
► Check the filters regularly.
1
Housing cover
2
Filter element
3
Filter housing
1
1
2 3
2
3
 Depressurize the system.
1
Open the housing cover.
2
Remove the filter element.
3
Clean or replace the filter element.
 For reassembly, proceed in reverse order.
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Maintenance
7.2.9
Gear metering pump
Sealing fluid
1
Seal housing
2
Grease nipple
3
De-aeration screw
4
Gear metering pump
5
Sealing fluid outlet
The seals of the metering pump are located inside a seal housing which is filled with
sealing fluid. The sealing fluid protects the seals from contamination, seals off the
material from the ambient air and its humidity, cools and lubricates the seals. Mesamoll grease is preferably used as a sealing fluid.
The housing is already filled at the time of delivery.
1
2
3
4
5
 The sealing system must be flushed with new blocking fluid by using a commercially available grease gun every three months.
 Flush the housing until clean blocking fluid comes out of the blocking fluid outlet.
NOTICE
Damages on the seals.
Applying too much pressure may damage the seals.
► Slowly press the blocking fluid into the seal housing with little pressure.
Sealing systems
If blocking fluid or material flows out of the blocking fluid outlet during operation, this
is a sign for leakages in the sealing system. In this case, the sealing system requires
maintenance. However, slight leakages are normal.
The gear pumps can be fitted with different seals. The type description specified on
the nameplate of the gear pump contains the information of each version. The
nameplate and the rotating direction arrow are attached on the external perimeter of
the gear pump.
Apart from that, the sealing systems (versions URF, RSS, VCR and MSE) are maintenance-free. In case of leakage, replace the sealing system of the pump.
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Maintenance
7.2.10
Discharge system
The discharge system may be equipped with an adjustable seal. A few drops of oil
or DINP sealing liquid can extend the service life of the seal. In case of vertical installation position, you can let drip the lubricant from the piston rod into the gland nut.
Piston rod seal with Vsleeves
1
Gland nut
2
Piston rod
Retighten the packing:
 Use an arbor to tighten the gland nut (torque approx. 20 Nm to 30 Nm).
2
1
Fig. 7-1 Static discharge system
7.2.11
Diaphragm vacuum pump
The vacuum pump is maintenance-free under normal load. Valves and diaphragms
as well as the motor capacitors are wear parts. If the pump does no longer reach its
nominal pressure values after long time of use or if you hear a louder running noise,
the time for maintenance has come. Clean the pump chamber, diaphragm and
valves and also check the diaphragm for cracks. See the accompanying documentation chapter for detailed information.
7.2.12
Liquid separator
The liquid separator has been installed upstream the vacuum pump inlet. It collects
material and condensed vapors. Check on the sight glass whether there are any liquids in the separator. Any liquids present must be removed.
 Switch off the vacuum pump.
 Depressurize the system.
 Pull the lock downwards and rotate the vessel in counterclockwise direction.
 Empty and clean the vessel.
 Attach the vessel and turn it in clockwise direction until it snaps in.
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Maintenance
7.2.13
Touch screen
Touch screen
Use a wet cloth with cleansing agent to clean the unit (washing-up liquid or foaming
screen cleaning agent). Do not spray the cleaning agent directly on the touch
screen, but only on the cleaning cloth. Do not use any aggressive solvents or scrubbing agents.
NOTICE
Clean the touch screen.
If the touch screen is switched on, functions could be unintentionally triggered when
the buttons are touched (maloperation).
► Clean the touch screen only when it is switched off and do not clean it using
compressed air or a steam blaster.
1
Protective film
For EDP no., see the
parts list
1
Protective film
The adhesive protective film prevents the scratching and staining of the touch
screen and can be removed without any adhesive residues. It reduces reflections in
case of adverse lighting conditions. Use the operating unit only with attached protective film. Clean the film regularly and replace it as required.
NOTICE
Remove the protective film.
Objects with sharp edges or pointed objects can damage the touch screen.
► Do not use any objects with sharp edges or pointed objects to remove the protective film.
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Maintenance
7.3
Calibrate touch-screen
When a field on the touch-screen is touched and it does not react or an adjacent field
reacts, it may be necessary to calibrate the touch-screen.
 Press the
button.
 Select the "Touch-screen" menu.
 Press the "Calibration" button.
• A cross is displayed on the touch-screen.
 Press each of the displayed crosses.
• When the last cross has been pressed, calibration is completed.
7.4
Software information
The software number can be displayed.
 Press the
button.
 Select the "Machine information" menu.
• The software number is displayed.
In case of any queries on the control unit and the software, the information regarding the software name and version is required.
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Maintenance
7.5
Metering control unit software change
The MR40 has an internal boot loader. The boot loader executes automatically a
new application loading or a software update.
This binary file is processed like a "normal file" with Windows-Explorer on a commercially available PC functioning with Windows. This allows e.g. to send an update per
e-mail. The service technician or the customer then just copies the file onto a commercially available USB stick.
Now the software can be downloaded permanently from the USB stick via the USB
interface (4.6.5 MR40) into the program memory (Flash).
1
USB stick
2
USB port
3
Control unit MR40
3
1
2
Please note that the machine data are no longer available after the software
has been changed. The machine data should thus be recorded or, even better,
be saved provided the control unit is able to do so.
 Switch off the machine using the main switch.
 Insert the USB stick containing the "MR40.BIN" file into the USB port on the control cabinet or directly into the MR control unit.
 Switch on the machine using the main switch.
• The file is loaded.
• Any previous software is overwritten.
• The program is started.
• If the USB stick does not contain the file "MR40.BIN", the software in the
flash memory is started.
 Remove the USB stick.
Software management: First, rename an older software version, e.g. into
"MR40_V1.0.BIN". New updates should always be provided with the current
version number in the file name, e.g. "MR40_V3.3.BIN". For loading in the
CPU, this file on the memory stick must be renamed into "MR40.BIN" with Windows-Explorer.
The LED "Status" signals the corresponding condition of the CPU.
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"Status" LED
CPU condition
Slow blinking 1 Hz
Application not loaded and/or started,
CPU in "HOLD" mode
Fast blinking 10 Hz
The application is being currently loaded from the
memory stick and programmed into the flash memory
of the CPU.
Permanently ON
Application is started, CPU in "RUN" mode
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Maintenance
7.6
Machine data
The machine data, i.e. all settings carried out in the "Parameterization" and "Configuration" menus, can be saved and restored.
1
USB stick
2
USB port
3
Control unit MR40
3
1
2
Save
 Insert the USB stick into the USB port on the control cabinet or directly into the
MR control unit.
 Press the
button.
 Select "Data management".
 Press the "Save" key.
• The file "MR40_WP.DAT" for the metering program is written.
• The file "MR40_MP.DAT" for the machine data is written.
Restore
 Insert the USB stick on the MR control unit.
 Press the
button.
 Select "Data management".
 Press the "Restore" button.
• The files are read and the menus are restored.
Note that existing files on the USB stick with the same name will be overwritten. If different versions must be saved, the file names must be renamed.
7.7
Data storage
The parameter settings, program and machine data as well as the current working
hour meter data, can be created as a list and saved on a USB stick. The files can
then be stored in a PC, e.g. as Excel file.
 Insert the USB stick into the USB port on the control cabinet or directly into the
MR control unit.
 Press the
button.
 Select the "Data management" menu.
 Press the "Export CSV" key.
• The file MPAR.csv is written to the USB stick.
 Remove the USB stick.
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Maintenance
7.8
Buffer battery
The MR40 features a real-time clock with date and calendar function that is supplied
with 3.3 V through the internal power supply unit when the 24 V supply voltage is
switched on. When the supply voltage is switched off, a buffer battery ensures the
further operation of the real-time clock.
The buffer battery is a commercially available 3 volt lithium coin battery with the type
designation CR1220 that is mounted on the board base and thus can be easily replaced when it is depleted.
The battery voltage is constantly monitored during operation and a message is issued when it falls below a critical limit value. After replacing the battery, the time and
date must be entered anew on the operating panel.
1
Coin battery CR1220
2
Cover fastening
3
Screw to fasten the cover
1
2
3
Battery replacement
 Loosen 4 cover fastening screws.
 Remove the housing cover.
 Carefully press the spring plate visible at the right edge of the battery base using
a small screwdriver or similar tool from above to the right and lever out the coin
battery.
 Insert a new coin battery with the negative pole towards the board and carefully
press the spring plate to the left as necessary until the coin battery snaps into
place.
 Mount the housing cover and fasten it using the four cover fastening screws.
 Switch on the supply voltage.
 Enter the date/time again on the operating panel.
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Disposal
8
Disposal
8.1
Disposing of the system
Check the reusability value of materials and system parts prior to disposing of them.
Recycle them as much as possible.
Careless or incorrect disposal can result in unforeseen consequences. Materials
and system parts should be disposed of in a manner that is proven to be harmless
to humans, nature and the environment. Note the details provided by the manufacturers and observe the legislation and regulations of the particular country.
Dispose of elements and system parts separately according to type of material:
•
•
•
•
•
Aluminum from scrap steel
Copper and non-ferrous heavy metals in electrical parts and conductors
Batteries
Plastics
Organic substances, such as timber
Recycle as much as possible.
8.2
Final system decommissioning
For final system decommissioning, first of all, empty the material-carrying parts.
These parts include the material vessel, delivery pumps, metering pumps, hoses/
tubes, the mixing block, volumetric flow meters.
If the machine is equipped with a heating system, the system must first of all
be warmed up. The machine can only be emptied if sufficient fluidness of the
material is guaranteed.
Emptying the machine:
 Switch on the heating system and heat up the material (if present).
 Extract residual material from the container.
 Switch off the heating system (if present).
WARNING
Danger of burning!
System components are heated. Touching these parts when hot can result in serious
burns.
► Only touch heated components when cool.
Flushing the machine:
 Fill the material vessel with a suitable solvent (3.7 Flushing and cleaning the
system).
NOTICE
Dispose of material residues correctly and in accordance with local regulations.
 Disconnect the machine from compressed air supply.
 Carefully discharge residual air pressure from all parts, from the material vessel
by detaching compressed-air connections, from the lines by opening air relief
valves or the dispensing valve or by carefully loosening the line connections.
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Disposal
 If present, empty hydraulic lines, hydraulic tank and hydraulic cylinder.
 Make sure that no component is under pressure.
 Isolate the machine from the power supply unit.
 Remove any installed batteries and accumulators (back-up functions).
 Make sure that that all electrical connections have been disconnected and that
voltage is no longer supplied to any point.
Dismantling
parts:
The machine is now fully decommissioned and can be dismantled.
 Dismantle the system from the top to the bottom and by components.
 If you are able to reuse individual components in other systems, clean them
carefully and check them for wear and defects. Have these parts overhauled by
DOPAG.
 Preserve the reusable components by appropriate packaging before storing
them.
Dismantle the non-reusable components and separate them according to materials. Dispose of the parts professionally and correctly.
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Conformity and protocols
9
Conformity and protocols
This chapter contains certificates, acceptance reports, and declarations of conformity for your system.
Here, you will only find the main files in printed form. All files relevant to this
chapter are in the enclosed USB stick.
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Conformity and protocols
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Parts lists
10
Parts lists
This chapter contains the spare parts lists, spare parts drawings and dimension
sheets for your system.
Here, you will only find the main files in printed form. All files relevant to this
chapter are in the enclosed USB stick.
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Parts lists
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Circuit diagrams
11
Circuit diagrams
This chapter contains pneumatic, hydraulic, and electrical diagrams for your system.
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Circuit diagrams
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Accompanying documentation
12
Accompanying documentation
This chapter contains all documents related to parts of individual components and
third-party suppliers.
Here, you will only find the main files in printed form. All files relevant to this
chapter are in the enclosed USB stick.
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Accompanying documentation
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Material data
13
Material data
In this chapter you will find the documentation on the materials that can be processed with this system (3.1 Intended use).
Here, you will only find the main files in printed form. All files relevant to this
chapter are in the enclosed USB stick.
In case this information is missing, it was not available to DOPAG at the time
of delivery. Please update and complete these documents with the corresponding material and safety data sheets.
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Material data
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Customer documents
14
Customer documents
This chapter is intended for you to add your own notes and documents.
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Customer documents
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15
Key Word Index
A
Actuating elements 29
B
Back suction effect 68
Battery 112
C
circuit diagrams 121
Commissioning 49
Compressed-air maintenance unit 102
Configuration 35 54
Conformity 115
Connection 51
Electrical connection 51
Construction 20
Control unit 20
MR 40 45
Cross-references 8
D
Danger from
Cleaning 17
combustible materials 14
Electric power 14
Flushing 17
high pressure 15
toxic materials 14
Data
enter 53
Data storage 111
Decommissioning 75
De-aeration 41 66
Gear metering pump 65
De-aeration valve
Flushing 67
De-aeration valve with blocking attachment 26
Diagnosis 34
Discharge pressure 41
E
Electrical connection 43
Evacuation 64
Exhaust air 52
F
Filling
Vessel 63
Filling level check 42
Flow rate adjustment
automatic 41
interpolate 41
G
Gear metering pump 24
Gear pump
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Adjusting 69
H
Hazardous zones 14
I
Inspection 52
Installation 50
Intended use 13
Interface flow diagram 81
K
Keeping
the operating instructions 7
Konformität 18
L
Language selection 52
Leakage check 42
Level probe 24
Setting 61
Limit values 53
Log-in 39
M
Machine data
Saving 111
Main menu 31
Maintenance unit 21
Mandatory signs 11
Margin column 8
Material 44
Material data sheets 125
Material filter 23
Material filters
warten 105
Material lines
Maintenance 101
Material vessel 22
Metering
continuous 40
Program 40
shotwise 40
Metering quantity check 42
Mixing ratio
Control 42
correction 74
Mixing ratio control 40
N
Nameplate 11
O
Opening stroke 68
Operating data recording 42
Operating Instructions
Modifications 8
Object 7
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Operating location 49
Overview 33
P
Packaging 49
Parameter group 35 36
Parameter value
enter 53
Parameterization 36
Parameterizing 59
Plastic mixer 27
Potlife check 41
Pressure monitoring 41
Pre-run 40
Process data 33
Product safety 13
Prohibition signs 10
Protective film 108
R
Recirculation 26 40
Regeneration 42
Responsibilities of the operating company 16
Restore
machine data 111
S
Safety information 9
Safety regulations 13
Sealing liquid 98
Sealing systems 44
Seals 99
Setpoint values
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change 31
Silica gel
Color 103
Software change 110
Sources of danger 14
spare parts 97
spare parts drawings 119
spare parts lists 119
Starter
Reset 95
Status 37
Stirring 41
Switch OFF 85
Symbols 8
T
Target audience 7
Temperature 44
Terminals 45
Transportation 49 49
U
Umgebungsbedingungen 44
User administration 58
V
Vacuum pump
Diaphragm 28
Volume counter 25
adjusment 70
W
Warning signs 10
Warranty and liability 18
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Käfertaler Straße 253
68167 Mannheim | Germany
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1027206-1
Machine No.:
Original instructions