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WESTOMAT

AUTOMATIC DOSING UNIT for ALUMINIUM


MELT
in DIE-CASTING
00-B.doc

Version: 03.00 A

OPERATING MANUAL
WESTOMAT CONTROL

DPC

WESTOMAT P ro Dos DPC


OPERATING MANUAL

00.

2-2

00-B.doc

Version: 03.00 A

DOSING CONTROL

ST RIKO W EST O F EN GmbH


Lorenz-Schott-Strasse 5

D - 5 5 2 5 2 MA I N Z - K A S TE L Germany
T e l e p h o n e : + 49 (0) 6134 207 6
F a x: + 49 (0) 6134 207 877
E - m a i l : info@wiesbaden.strikowestofen.com
Fritz-Kotz-Strasse 2-4

D - 5 1 6 7 4 W I E H L - B O MI G Germany
T e l e p h o n e : + 49 (0) 2261 7091 0
F a x: + 49 (0) 2261 7091 107
E - m a i l : info@wiehl.strikowestofen.com
h t t p : / / www.strikowestofen.com

VERMERK

Diese Dokumentation ist urheberrechtlich geschtzt und darf nur zu internem


Gebrauch in Ihrem Werk eingesetzt werden.
Jede Vervielfltigung sowie jede Nutzung auerhalb Ihres Werkes ist untersagt.
Smtliche nicht ausdrcklich eingerumten Rechte bleiben vorbehalten.

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0000-B.doc

Version: 03.00 B

CONTENTS
NOTE

1-2

00.00

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


P ro D os DPC software versions: DPC V1.01-05 and higher.

00.

COVER PAGE

Version 0 3 . 0 0 A

00.00

CONTENTS

Version 0 3 . 0 0 B

HARDW ARE

Version 0 3 . 0 0 A

P ro D os DPC - WESTOMAT CONTROL


SYSTEM
SWITCHING P ro D os DPC ON / OFF
FRONT PANEL ELEMENTS

DESCRIPTION OF DISPLAY

TEMPERATURE DISPLAY

OPERATING KEYS
LIST OF INPUT / OUTPUT SIGNALS

Version 0 3 . 0 0 A

OPERATIONAL FUNCTIONS

Version 0 3 . 0 0 A

OPERATIONAL FUNCTIONS - GENERAL


DOSING

DOSING VOLUME (DATA SHEET)

DOSING VOLUME NEW / CORRECTION

Version 1 2 . 9 9 A

INTERFACE: WESTOMAT - DCM


FURNACE FILLING LEVEL INDICATION
FURNACE HEATING
OPERATING MODES

Version 1 2 . 9 9 A

OPERATOR INTERFACE

Version 1 2 . 9 9 A

STRUCTURE OF OPERATOR INTERFACE

Version 1 2 . 9 9 A

DOSING OPERATION (ON / OFF)

Version 0 3 . 0 0 A

SWITCHING DOS ON- / OFF - GENERAL


SWITCHING MANUAL DOS ON / OFF
SWITCHING AUTO DOS ON / OFF

Version 0 3 . 0 0 A

DISTURBANCES

Version 0 3 . 0 0 A

DISTURBANCES - GENERAL
STATUS DISTURBANCES
PROCESS DISTURBANCES AT WESTOMAT
PROCESS DISTURBANCES AT DCM

Version 0 3 . 0 0 A

01.
01.00

01.00.1
01.01
01.01.1
01.01.2
01.01.3
01.02

02.
02.00
02.01
02.01.1
02.01.2
02.02
02.03
02.04
02.05

03.
03.00

04.
04.00
04.01
04.02

05.
05.00
05.01
05.02
05.03

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WESTOMAT P ro Dos

CONTENTS

DPC
OPERATING MANUAL

2-2

00.00

06.
06.00
06.01
06.02
06.03
06.04
06.05
06.06
06.07
06.08

07.
07.00
07.01
07.02
07.03
07.03.1
07.03.2
07.03.3
07.04
07.04.1
07.04.2
07.04.3
07.04.3.1
07.04.3.2
07.04.3.3
07.04.3.4
07.04.4
07.04.4.1
07.04.4.2
07.05
07.05.1
07.05.2

0000-B.doc

Version: 03.00 B

DOSING CONTROL

HELP FUNCTIONS

Version 0 3 . 0 0 A

GENERAL DESCRIPTION
ERROR HISTORY
INPUT / OUTPUT LEVEL
CYCLE COUNTERS
DATA DISPLAY
i / T (INFO - TEMPERATURES)
/ T (INPUT TEMPERATURE VALUES)
PRINTER
MEMO .

Version 1 2 . 9 9 A

SETUP MODE

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Version 1 2 . 9 9 A

GENERAL INSTRUCTIONS

Version 0 3 . 0 0 B

LDT: LANGUAGE / DATE / TIME

Version 0 3 . 0 0 B

Version 0 3 . 0 0 B

LOG DATA
REGULATOR-HEATING (GENERAL)

REGULATOR CONFIGURATION

TEMPERATURE REDUCTION

FIRST WARM-UP
FILLING LEVEL INDICATION - GENERAL

DISPLAY MODE

SWITCHING THRESHOLD (of lamps)

CELL-FILLING LEVEL SYSTEM - GENERAL


DATA ENTRY .
CELL-mA-SIGNAL
CELL - P/t-MIN-MEASURING
SIGNAL COMPENSATION .

HPDE-FILLING LEVEL SYSTEM - GENERAL


DATA ENTRY
HPDE - P/t-MIN-MEASURING
kg-DIAGRAM

REFERENCE-(DOSING)-VOLUMES RDV

OPERATING DATA

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WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE

0100-B.doc

Version: 03.00 A

1-4

ProDos DPC - WESTOMAT CONTROL


SYSTEM

01.00

The Pro Dos DPC control is a compact,


microprocessor-controlled digital system for the
process control and process regulation, operation and
visualisation of the WESTOMAT the automatic dosing
system designed for the dosing of aluminium melt.
The system's CPU consists of heavy-duty industrial
electronic elements and can be integrated in the front
panel of the switch cabinet door. The CPU is equipped
with:

integrated power supply unit for the supply with


230V AC and battery buffer to protect saved
programme parameters against loss.
integrated digital input and output modules

integrated analog modules for the control of a


proportional valve including interfaces for pressure
measuring converter and NiCrNi thermocouples

integrated temperature regulator for temperature


holding operation of the furnace

pluggable terminals for all electric connections

data transmission interface for remove diagnosis


(by means of printer, PC, modem ) for the
reading of process data and set-up parameters

data transmission interface for the loading of


software

protective cover at the rear side


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

back-lit LC display for the visualisation and


operator guidance by means of text in selected
language

eight-segment display of desired and actual


melt temperature

numerical keyboard

five multi-function keys (below display ; the


available functions are shown in the respective
text fields of the display)

eight help menu keys (availability indicated by


LEDs)

The Pro Dos DPC is equipped with the following


operational functions:

DOSING TECHNIQUE:

Furnace
pressure
control
system
with
proportional inlet valve and measuring pressure
converter

HARDWARE

Pro Dos DPC - the WESTOMAT Control


System
01.00

2-4

0100-B.doc

Integral calculation of the dosing process for


accurate definition of dosing volumes and
repeated processing

Options for dosing contact (DC): by means of


sensing electrode or pneumatic contactor
(PneuCo) at the outlet of the dosing pipe

Input menu for adjustment of dosing volume

Modification menu for selective modifications of


dosing data.

CONTROL TECHNOLOGY:

Proven and standardised signal interface


between WESTOMAT dosing unit and diecasting machine (DCM) for save, monitored and
coordinated processing

Automatic optimisation system for cycle


synchronisation of WESTOMAT processes with
closing movement of DCM-die, reducing cycle
time per cast (t9 = cast time of DCM).

TEMPERATURE REGULATION SYSTEM:

Temperature
monitoring
by
means
of
thermocouple in melt and regulation of holding
temperature with automatic switching of furnace
heating

Monitoring of parameter-controlled quality


thresholds of holding temperature fore melt with
dosing lock

Monitoring of parameter-controlled limit values


for HEATING ALARM to prevent solidification
or overheating of melt

Monitoring of furnace temperature

EMERGENCY HEATING programme, to be used


in the event of defect in melt thermocouple

Programmable weekend temperature reduction


for melt

Automatic warm-up programme for cold start of


furnace.

FURNACE FILLING LEVEL INDICATION:

Filling level scanning options: by means of load


cell (CELL) or hydraulic-pneumatic pressure
detection system (HPDE)

Five indicator lamps, which can be programmed


to indicate various filling levels and thresholds.

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE

Pro Dos DPC - the WESTOMAT Control System


0100-B.doc

Version: 03.00 A

3-4

01.00

SETUP PROGRAMME:

To be used during commissioning and for the


entry of unit-specific operating parameters:

LOG data of all setup procedures with


automatic date registration

Setup of temperature regulators with plantspecific parameters

Setup of filling level indication and rate of


furnace chamber pressure rise for dosing

Setup for dosing-pipe specific data, e.g.


dosing volume range between smallest and
largest possible dosing volume

Setup of time, date and language of user


interface.

ATTENTION

SETTINGS MAY ONLY BE MADE BY QUALIFIED


AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

The SETUP mode can be protected against


unauthorised manipulation by a code lock with
customer-specific SETUP CODE LOCK NUMBER:

SETUP PROGRAMME:

Setup for selection of operating modes for


dosing and heating.
ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

The SETUP mode can be protected against


unauthorised manipulation by a code lock with
customer-specific OPERATING MODE CODE
LOCK NUMBER:

HELP FUNCTIONS:

Error history - display of the last fifty error event


with time, date and error message

Input/output level - display of the switching


status and simulation of the output status, of
special use for testing and diagnosis

Cycle counters

Display of all measured process values, log


data and StrikoWestofen service telephone
numbers.

Information on temperatures - display of actual


and nominal furnace temperatures

HARDWARE

Pro Dos DPC - the WESTOMAT Control


System
01.00

4-4

0100-B.doc

Entry in C (F) of nominal value and quality


limit value (undertemperature/overtemperature)
for melt temperature

Activation of data output interfaces for individual


process data (dosing data, disturbances, log,
regulator configuration) or output of entire
dosing process data log

MEMO - key for saving data in setup mode

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

01001-B.doc

Version: 03.00 A

1-2

01.00.1

SWITCHING P ro D os DPC ON / OFF

The Pro Dos DPC is switched ON and OFF by means


of the main switch at the W E S T O M AT switch
cabinet.

SW IT CHING ON
By activating the main switch, power (230V AC - 50/60
Hz) is supplied to the CPU is and the following
processes take place:

***BASIC STATUS***
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or

10.03.00
HEATING
13:34:57
SCAN=CELL
F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

Automatic loading of the saved setup data


(protected against data loss by buffer battery) to
the RAM of the Pro Dos DPC

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


10 sec.), the Pro Dos DPC is in BASIC STATUS
and, depending on the W E S T O M AT equipment,
the following operational functions are active or
available:

FURNACE HEATING is available:


- if the temperature control is carried out by means
of the internal regulator of the Pro Dos DPC
(HEATING - see display field right top corner)

FURNACE LEVEL INDICATION is active:


- if the fill level indication is carried out by
means of a load cell (SCAN=CELL - see display
field right top corner)

DOSING OPERATION is available:


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

MULTI-FUNCTION

KEYS

(F1

to

F5)

are

available:
- see respective function descriptions in the
associated display fields

HELP MENU KEYS are available:


- see Chapter 06 of the Operating Manual.
***BASIC STATUS***
10.03.00
HEATING
13:34:57
SCAN=CELL
DOS. PIPE 65/21mm
F4 = kg-DOS: NEW
!

ATTENTION

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

if no entry of a dosing volume has been made

P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

The BASIC STATUS of the Pro Dos DPC is not


fully completed:
and saved in the main memory:
- see text in info line.

HARDWARE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SWITCHING Pro Dos DPC ON / OFF


01.00.1

2-2

01001-B.doc

Version: 03.00 A

DOSING CONTROL

ATTENTION
The BASIC STATUS of the Pro Dos DPC is not
displayed if the settings previously entered in setup
mode are not completed and saved in the main
memory - e.g.:

setup mode for kg-DIAGRAM not completed and


saved in the main memory:

SETUP MODE:

- see text in info line.

F1:
F2:
F3:
F4:
F5:

DATA

F1

By switching off the main switch at the W E S T O M AT


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

All operational functions of the Pro Dos DPC are


switched off

All entered and saved data and settings for


OPERATING MODES are saved in the main
memory of the Pro Dos DPC (protected against
data loss by buffer battery).
ATTENTION
By switching off the main switch at the
W E S T O M AT switch cabinet, the furnace heating
is also switched off. Idle times of more than approx.
6 hours result in:

Cooling of the furnace chamber

Solidification of the residual melt in the furnace

Damage to the ceramic parts immersed in the


melt

HEATING
SCAN=CELL

SETUP of OPERATING DATA for:


LOG DATA ......................
FILL LEVEL INDICATION .........
LDT - LANGUAGE/DATE/TIME ......
kg-DIAGRAM ....................
REGULATOR DATA and HEAT-FUNCT..

LOG

SW IT CHING OFF

10.03.00
13:34:57
F4 = kg-DIAGRAM !

FILL
LEVEL

F2

LDT
SETUP

F3

=
=
=
=
=

1
1
1
0
1

kg-DIA- REGULAT.
GRAM
HEATING

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE

0101-A.doc

Version: 12.99 A

1-2

FRONT PANEL ELEMENTS

01.01

The Pro Dos DPC is designed as a front panel device


and integrated in the switch cabinet door. The front
panel is secured on the switch cabinet door by means
of screws and a frame seal.

The front panel includes a visualisation field and the


operating elements of the system:

Keyboard with eight keys of the help menu:


- see chapters 01.01.3 and 06.00

Four arrow-keys to move the cursor in the


visualisation field of the display:
- see chapter 01.01.3.

a numeric keyboard for the entry of (numerical)


data:
- see chapter 01.01.3

Row of five multi-function keys (F1 to F5); the


current functions of the keys are displayed in the
corresponding display fields:
- see chapter 01.01.3

Segmented display of the actual and desired melt


temperature:
- see chapter 01.01.2

Back-lit display:
- see chapter 01.01.1

HARDWARE

FRONT PANEL ELEMENTS


01.01

2-2

0101-A.doc

blank page

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE
FRONT PANEL ELEMENTS

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

01011-B.doc

Version: 03.00 A

1-4

DESCRIPTION OF DISPLAY

***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 100/35mm 13:34:57
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

01.01.1

The display of the Pro Dos DPC is separated into


several display fields. Their contents vary according to
the current status.
Example for the display in BASIC STATUS, after:

setup of:
LDT - Language / Date / Time (clock)
the LOG DATA
the FILLING LEVEL INDICATION
the kg-DIAGRAM
the REGULATOR CONFIG. (temp. regulator)

is completed, and:

a DOSING VOLUME and

the OPERATING MODES:


TOP-STOP
SYNCHRONIZATION
WEEK-END REDUCTION TEMPERATURE
EMERGENCY HEATING

have been set and saved.


DISPLAY FIELDS - Examples and EXPLANATIONS
The control is in BASIC STATUS mode:

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

OFFLINE:
27.65kg
DOS. PIPE 100/35mm

First line: BASIC STATUS


Second line: Size of pipe used in the current
dosing operation.

The control is in F5 STATUS or in DOSING STATUS:

First line: entered and saved dosing volume


Second line: Size of pipe used in the current
dosing operation.

The control is in SETUP MODE:

SETUP MODE:
LOG DATA

10.03.00
13:34:57

AUTO
SCAN=CELL

First line: SETUP MODE


Second line: according to the modified set-up
mode.

The control is in BASIC STATUS or in F5 STATUS:

First line: current date

Second line: current time

The control is in AUTO DOSING STATUS:

First line:current operating mode

Second line: furnace fill level indication by means


of pressure-load weighing cell (CELL) is active.

HARDWARE
FRONT PANEL ELEMENTS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DESCRIPTION OF DISPLAY
01.01.1

2-4

01011-B.doc

The control is in MANUAL DOSING STATUS:

First line: current operating mode

Version: 03.00 A

DOSING CONTROL

MANUAL
SCAN=HPDE

Second line: furnace filling level indication via


hydraulic-pneumatic pressure detection (HPDE) is
active.

The control is in BASIC STATUS or in F5 STATUS:

First line: temp. regulation of furnace heating via


internal regulator is active

Second line: furnace fill level indication by means


of pressure-load weighing cell (CELL) is active.

HEATING
SCAN=CELL

The control is in BASIC STATUS or in F5 STATUS:

First line: temp. regulation of furnace heating via


external regulator is active

Second line: furnace filling level indication via


hydraulic-pneumatic pressure detection (HPDE) is
active.

SCAN=HPDE

DOSING
... ON

The control is in MANUAL STATUS or in AUTO


DOSING STATUS:

First line: dosing operation is entered


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

INFO LINE
This line of the display shows important messages for
the operator, for example:

EXT. KEY DOS-ON or F5 = DOSING

The control is in BASIC STATUS; for dosing, press


external LED-key DOS-ON (installed at the switch
cabinet door or at the control panel), or press multifunction key F5 and then follow the instructions

The control is in F5 STATUS and the


EMERGENCY STOP key of the die-cast machine
(DCM) control is activated

The control is in DOSING STATUS or F5 STATUS


and the query result of the DCM signals returned
an incorrect position of the press plunger

the query result of the WESTOMAT stand-by for


dosing returned an incorrect status - the selected
operating mode TOP-STOP is not activated

the WESTOMAT and DCM are in stand-by for


MANUAL DOSING (in MANUAL)

DOSING by HAND = READY

in the AUTO-DOS operating mode, comments are


only displayed in the event of errors.

EXT. KEY DOS-ON or F5 = DOSING

ERROR: EMERGENCY STOP DCM / ESC=back

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

Position error: TOP-STOP / ESC=back

WESTOMAT ProDos DPC


OPERATING MANUAL

HARDWARE
FRONT PANEL ELEMENTS

DESCRIPTION OF DISPLAY
01011-B.doc

DOSING CONTROL

Version: 03.00 A

3-4

01.01.1

COMMENT AND VISUALISATION FIELD


Depending on the current operating mode, this field
displays detailed operating instructions or shows the
dosing process (visualisation of the DCM signals and
individual dosing steps):
*****

WESTOMAT - DOSING CONTROL

*****

The control is in BASIC STATUS:


the DPC-V .... software version, the set-up data
and the available residual melt in the furnace
are displayed

P r o D o s
DPC-V1.01-05 = DIE-CAST-VERSION
03.03.00
= DATE OF SETUP DATA

AVAILABLE = 1040 kg MELT

kg-DOS-RANGE:

12.50 to 22.35 kg

Form for the entry or modification of individual


parameters of a dosing volume file (kg-DOS: NEW)

17.65 kg = dosing volume (OFFLINE)


+ 0.75
kg = AUTO-increase up to 3.27
- 1.15
kg = AUTO-decrease up to 3.25
- 55.0
% = furnace chamber-CORRECTION
1.8
s = t5 - lag time
P-FD = 80 mbar / t4 = 3.55 s

Instruction displayed prior to saving a new entry

Instructions regarding DCM

F1 - SAVE DATA MODIFICATION


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

Instruction for AUTO-DOSING:


- switch DCM into AUTO !
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !

t6

t7

Visualisation diagram - WESTOMAT and DCMDIE are ready for MANUAL DOSING

Visualisation diagram - Process of WESTOMAT


AUTO-DOSING operation

DCM-DIE

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT

t6

t8

t7

DCM-DIE
TS=

t9
t1

t2

p = 57.49 mb

DC
t3

NC = 12725

t4

AC =

t5

HARDWARE
FRONT PANEL ELEMENTS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DESCRIPTION OF DISPLAY
4-4

01.01.1

01011-B.doc

Version: 03.00 A

DOSING CONTROL

DESCRIPTION OF MULTI-FUNCTION KEYS


The functions of the multi-function keys installed below
the display change according to the selected operating
mode - Examples:

The control is in BASIC STATUS. The key


functions are as follows:
F1 call up INFO
F2 call up SETUP MODE for
F3 call up OPERATING MODES
F4 call up entry for a new dosing volume
F5 initiate query for ready for dosing of the
WESTOMAT and the DCM-DIE

the SETUP MODE has been selected; continue


with keys:
F1 - to DATA LOG
F2 - to FILL LEVEL INDICATION
F3 - to LDT = Language / Date / Time
F4 - to kg-DIAGRAM
F5 - to REGULATOR HEATING

F1

The control is in DOSING STATUS; continue with


keys:
F1 displays operator INFO
F3 allows for the modification (correction) of
dosing parameters

INFO

The brightness of the display can be adjusted


continuously by means of the following keys:
hold

and key

or

or:

LOG
DATA

MEMO
= YES

In order to protect the screen, the display illumination


is automatically switched off. It can be switched on by
pressing any key.

F1

After entry of new values, the MEMO has been


pressed; continue with keys:
F1 = save
F3 = do not save
F5 = back to data entry

DISPLAY ILLUMINATION

INFO

press and hold

and hold

or

F1

F1

SETUP

F2

FILL
LEVEL

F2

OPERAT. kg-DOS:
MODES
NEW
DOSING

F3

LDTSETUP

F3

F4

kg-DIA- REGULAT.
GRAM
HEATING

F4

MEMO
= NO

F2

F3

F5

F5
BACK TO
ENTRY

F4

F5

F4

F5

MODIFY
DATA

F2

F3

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE
FRONT PANEL ELEMENTS
01012-B.doc

Version: 03.00 A

TEMPERATURE DISPLAY

1-2

01.01.2

The Pro Dos DPC front panel is equipped with a


segmented digital display for the temperature of the
melt. The selection of an internal or external regulator
as well as the display in C or in F is made in the log
of the control.
This display is only available if an internal temperature
regulator is selected:

694
W

695

X = current ACTUAL VALUE of melt temperature

W = DESIRED VALUE of melt temperature.

ATTENTION
In the event of an ERROR: HEATING ALRAM: both
displays (X and W ) are blinking.
If the EMERGENCY HEATING mode is selected, X
= current ACTUAL VALUE of the melt temperature
is blinking and the displayed value does not
correspond to the actual value.
In the event of failure of the thermocouple
(ERROR: HEATING ALARM) the displayed
temperature value does not correspond with the
actual value.

HARDWARE
FRONT PANEL ELEMENTS

TEMPERATURE DISPLAY
01.01.2

2-2

01012-B.doc

blank page

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE
FRONT PANEL ELEMENTS
01013-A.doc

Version: 12.99 A

1-4

OPERATING KEYS

01.01.3

The Pro Dos DPC is equipped with the following


operating keys at the front panel:

NUMERICAL KEYBOARD with the


functions:

Input keys

Key
values

Keys

to

following key

and

for the entry of positive/negative

and

, together with key .

for the adjustment of the brightness of the


display

Key

ESC to exit the current menu

and return to BASIC STATUS

Key
pressing

CLR for deleting an entry (prior to

ENTER)

Key

Key

is currently not used

Key

is currently not used.

= ENTER to confirm an entry

Five MULTI-FUNCTION KEYS, located below the


display, with various functions:

The functions of key


on:

F1

to

F5 depend

- current operating mode of the control;


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

HARDWARE
FRONT PANEL ELEMENTS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING KEYS

01013-A.doc

2-4

01.01.3

HELP MENU KEYS (with LEDs) to access the


HELP FUNCTIONS of the Pro Dos DPC:
- see chapter 06.00

Key

ERROR HISTORY

to activate

the ERROR HISTORY help function - display of


error list
- see chapter 06.01

Key

I / O LEVEL

to activate

the following help functions:


SET DIG-OUT
- WESTOMAT-DCM SIGNALS- display
- DIGITAL IN / OUT - display
- ANALOG IN / OUT - display
- see chapter 06.02

Key

CYCLE COUNTER

to activate

the following help functions:


- Display and delete total and shift cycle counter
of injections and errors
- see chapter 06.03

Key

DATA DISPLAY

to activate

the following help functions:


- CYCLE DATA display data table
- SETUP DATA - display data table
- see chapter 06.04

Key

i/T

to activate the

help function
- Display of table of ACTUAL VALUES /
NOMINAL VALUES of the temperature holding
operation:
- of the melt
- in the furnace chamber
- operating hour counter of the heating
- see chapter 06.05

Version: 12.99 A

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE
FRONT PANEL ELEMENTS

OPERATING KEYS
01013-A.doc

Version: 12.99 A

3-4

Key

01.01.3

/T

to activate the

help function
- Entry of operating values of the holding
temperature of the melt:
- NOMINAL VALUE MELT
- UNDERTEMPERATURE MELT
- OVERTEMPERATURE MELT
- see chapter 06.06

key

PRINT

to activate

the help functions for data output to the


PRINTER interface:

INDIVIDUAL OUTPUT of:


- DOSING DATA HISTORY
- ERROR HISTORY
- LOG DATA
- REGULATOR CONFIGURATION

CYCLICAL / CONTINUOUS output of:


- CYCLIC DOSING DATA
- CYCLIC QUALITY DATA
- CYCLIC MEASURING VALUES (for PC)
- see chapter 06.07

Key

MEMO

to save

entries and settings.


- see chapter 06.08.

four ARROW KEYS to move the cursor in the


visualization field:
- up, down, left and right.

HARDWARE
FRONT PANEL ELEMENTS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING KEYS
01.01.3

4-4

01013-A.doc

blank page

Version: 12.99 A

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HARDWARE

0102-A.doc

Version: 12.99 A

1-2

LIST OF INPUT / OUTPUT SIGNALS

I-NO.

I = DIG IT AL INPUT SIG NALS

01.02

PLUG CONNECTOR

TERMINAL
NO.

I-01
I-02
I-03
I-04
I-05
I-06
I-07
I-08

dosing contact ................................ (minus-switching)


EMERGENCY STOP by W ESTOMAT
EMERGENCY STOP by DCM
undertemperature melt ........... (with external regulator)
overtemperature melt ............. (with external regulator)
cleaning door locked
pressure switch furnace chamber
dosing ON

TB 2. P 2

6
5
10
9
14
13
18
17

I-09
I-10
I-11
I-12
I-13
I-14
I-15
I-16

furnace ready for injection


dosing by hand
acknowledge disturbance
acknowledge horn
n/a
refill cover OPEN
heating ON
monitoring PneuCo

TB 2. P 3

6
5
10
9
14
13
18
17

I-17
I-18
I-19
I-20
I-21
I-22
I-23
I-24

auto-fill test
auto-operation ON
die closing
die closed 1
die closed 2
die ready for injection 1
die ready for injection 2
plunger in back position

DCM
DCM
DCM
DCM
DCM
DCM
DCM
DCM

TB 2. P 4

6
5
10
9
14
13
18
17

I-25
I-26
I-27
I-28
I-29
I-30
I-31
I-32

discontinue synchro. operation


kg-reduction
kg-increase
n/a
n/a
n/a
n/a
n/a

DCM
DCM
DCM

TB 2. P 5

6
5
10
9
14
13
18
17

AI-NO.

AI = ANAL O G INPUT SIG NAL S

AI-01
AI-02
AI-03

mV-NiCrNi: thermocouple melt


mV-NiCrNi: thermocouple furnace chamber
4 to 20 mA: furnace chamber measuring pressure
converter (30 V DC)
4 to 20 mA: load cell ................................. (30 V DC)

AI-04

PLUG CONNECTOR

TB 2. P 4

+ TERMINAL NO.

6
9
1

/
/
/

4
7
3

HARDWARE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LIST OF INPUT / OUTPUT SIGNALS


2-2

01.02

O-NO.

0102-A.doc

Version: 12.99 A

O = DIGIT AL OUT PUT SIGNALS

DOSING CONTROL

Ampere
LOAD

PLUG CONNECTOR

TERMINAL
NO.

O-01
O-02
O-03
O-04

general disturbance .......... (collective relay)


horn
solenoid-lock - door locking
fill furnace ................... (for melting house)

0,5
0,5
0,5
0,5

TB 3. P 2

2
6
10
14

O-05
O-06
O-07
O-08

CPU enabled for dosing operation ON


test mode
n/a
ALARM heating

0,5
0,5
0,5
0,5

TB 3. P 2

1
5
9
13

O-09
O-10
O-11
O-12

metal supply in automatic


Metal filling in active
release for injection 1
release for injection 2

DCM
DCM
DCM
DCM

0,5
0,5
0,5
0,5

TB 3. P 3

2
6
10
14

O-13
O-14
O-15
O-16

disturbance metal supply


ready for dosing ON
n/a
n/a

DCM
DCM

0,5
0,5
0,5
0,5

TB 3. P 3

1
5
9
13

O-17
O-18
O-19
O-20

lamp
lamp
lamp
lamp

(FULL)
(92% = standard)
(69% = standard)
(46% = standard)

0,5
0,5
0,5
0,5

TB 3. P 4

2
6
10
14

O-21
O-22
O-23
O-24

lamp - furnace filling level (23% = standard)


lamp - ready for operation MANU/AUTO
lamp - dosing operation
lamp - disturbance

0,5
0,5
0,5
0,5

TB 3. P 4

1
5
9
13

O-25

TB 3. P 5

O-27
O-28

EMERGENCY STOP - pressurised air inlet


valve spool
EMERGENCY STOP - deaeration pilot valve
spool
valve spool - dosing pipe scanning
deaeration pilot valve spool

O-29
O-30
O-31
O-32

2
2
2
2

O-26

AO-NO.

furnace
furnace
furnace
furnace

filling
filling
filling
filling

level
level
level
level

bypass valve spool .... (intake press. air from DC)


n/a
heating stage 1 .......................... (full load)
heating stage 2 ...................... (partial load)

AO = ANALO G O UT PUT SIG NAL S

AO-01 analog signal for prop. valve pressure air inlet

2
2

5
7

SIGNAL

0 to 10 V

1
3
5
7

TB 3. P 6

PLUG CONNECTOR

TB 1. P 4

+ TERMINAL NO.

WESTOMAT ProDos DPC OPERATIONAL FUNCTIONS


OPERATING MANUAL

DOSING CONTROL

0200-A.doc

Version: 12.99 A

1-2

OPERATIONAL FUNCTIONS - GENERAL

02.00

The P ro D os DPC WESTOMAT control is equipped


with a range of programme options.

OPERATIONAL FUNCTIONS
Operational functions include all functions that
communicate with the WESTOMAT and its
environment via input/output connections:

Operational function DOSING:


- see chapter 02.01

Operational function DCM-INTERFACE:


- see chapter 02.02

Coordination of the processes of the


WESTOMAT and DCM, including automatic
synchronization and processing of special DCM
functions:
Quick tension test
Tension control during die closing
Automatic dosing volume REDUCTION
Automatic dosing volume INCREASE

Operational function FILLING LEVEL INDICATION:


- see chapter 02.03

Process regulation and control of the cyclic


release of a defined quantity of aluminium melt
to the DCM, including automated additional
options:
Dosing with or without TOP-STOP
Dosing with electrode or PneuCo
Dosing volume REDUCTION
Dosing volume INCREASE

Detection and indication of furnace filling level


including min. limit level monitoring and
signalling for refilling; filling level detection by
means of:
load cell (CELL)
hydraulic-pneumatic pressure detection device
HPDE (without CELL).

Operational function HEATING:


- see chapter 02.04

Full load/partial load OFF of furnace heating;


temperature regulation and monitoring of the melt
and furnace chamber temperature by means of:
Dosing-lock
at
undertemperature
or
overtemperature of the melt
First warm-up (cold start) of the furnace
Timer programme for weekend reduction of the
melt temperature.

OPERATIONAL FUNCTIONS

OPERATIONAL FUNCTIONS - GENERAL


02.00

2-2

Operational function
dosing and heating:
- see chapter 02.05

0200-A.doc

OPERATING

Version: 12.99 A

MODES

Dosing with or without TOP-STOP


Dosing with or without synchronization
Weekend reduction of melt temperature
EMERGENCY
HEATING
(without
thermocouple).

Operational HELP FUNCTIONS:


- see chapters 06.00 to 06.08
Error history
I/O level
Cycle counter
Data display
INFO of temperatures
Entry of nominal values (melt temperature)
Print
MEMO (saving).

Operational function SETUP MODE:

for

melt

At commissioning, the P ro D os DPC is


configured with WESTOMAT data and the
programmed setup procedures:
- see chapter 07.00

Setting time and date, selection language


and software version
- see chapter 07.01

Log data:
- see chapter 07.02
Entry of parameters
Inclusion and exclusion of functions:
Electrode or PneuCo
Internal or external temp. regulator
Temperature display in C or F
Filling level monitoring with CELL or
HPDE

Heating regulator and regulator configuration


parameters:
- see chapters 07.03 + 07.03.1 + 07.02.2
data for EMERGENCY HEATING
Temperature reduction
Selection of warm-up programme for
furnace cold start

Fill level indication with:


- see chapters 07.04+ 07.05
thresholds for FULL and EMPTY
Display mode of filling level lamps
Standard or customer-specific switching
thresholds of filling level lamps
Pressure and time values of dosing
contact and max. pressure ramp during
dosing

kg-diagram of dosing volume range:


- see chapter 07.06
for dosing pipe 1
for dosing pipe 2

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

0201-B.doc

Version: 03.00 A

1 - 10

DOSING

02.01

The operational function DOSING describes the


preparation for dosing and the DOSING processes of
the P ro D os DPC in connection with the DCM.

PREPARATIONS
Prior to the commencement of the dosing operation,
the following settings must be completed at the
P ro D os DPC:

Entry of DOSING VOLUME (in kg and according to the


cast incl. sprue) - see chapter 02.01.2 for additional
parameters:

with / without dosing volume INCREASE

with / without dosing volume REDUCTION

Transfer of % value of FURNACE CHAMBER


CORRECTION - adjustment is required, if the
dosing volume is continuously increased or
reduced when the furnace is gradually emptied.

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

Selection of OPERATING MODES - see chapter


02.05:

Operating mode with / without TOP-STOP

Operating mode
SCANNING

Operating
mode
SYNCHRONIZATION

10.03.00
13:34:42

HEATING
SCAN=CELL

, INPUT, ENTER and MEMO / ESC=back

2.5

= (Electrode = 1 / PneuCo = 0)
s = t5-DC (DC after deaeration)

INFO
DOSING

with

without
/

LEVELwithout

Standard - with SYNCHRONIZATION until


DIE CLOSED

Exceptions (e.g. three-plate die) - with


SYNCHRONIZATION until DIE READY FOR
INJECTION.

Operation with ELECTRODE:

This option is independent of the switching


mode (AUTO / MANUAL)

Dosing contact (DC) with the melt in the


dosing pipe by means of an electrode
attached to the dosing pipe

During the metal feed process, this electrode


is retracted from the melt area.

K02. DOSING CONTACT (DC) WITH:


1

Selection of OPERATING OPTIONS, selectable in


setup mode LOG K02 - see chapter 07.02:

SETUP MODE:
LOG DATA

with

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING
2 - 10

02.01

0201-B.doc

Operation with PneuCo:

This option is independent of the switching


mode (AUTO / MANUAL)

Dosing contact (DC) with the melt in the


dosing pipe by means of the automatic
closing of the PneuCo nozzle (pneumatic
contact) in the dosing pipe.

During the metal feed process, the PneuCo


pressure prevents the melt from penetrating
into this nozzle

Version: 03.00 A

DOSING CONTROL

10.03.00
13:34:42

SETUP MODE:
LOG DATA

HEATING
SCAN=
CELL

, INPUT, ENTER and MEMO / ESC=back


K02. DOSING CONTACT (DC) WITH:
0

= (Electrode = 1 / PneuCo = 0)

2.5

s = t5-DC (DC after deaeration)

INFO
DOSING

ATTENTION
The availability of these options depends on the
equipment of the WESTOMAT.
In addition to the selection of the options in the log,
the hardware switch in the switch cabinet must be
set to the appropriate position.

Activation of SWITCHING MODES by means of


selecting switch position at DCM:

Switching mode MANUAL - if I-18 = 0, DCM


control not set to AUTO (or semi-AUTO) - see
chapter 04.01

OFFLINE:
27.65kg
MANUAL
DOSING
SCAN=CELL
DOS. PIPE:100/35mm
... END
instruction / EXT.-KEY DOS-OFF
Instruction for AUTO-DOSING:
- Set DCM into AUTO !

Switching mode AUTO - if I-18 = 1, DCM control


set to AUTO (or semi-AUTO) - see chapter
04.02

Dosing process (in AUTO-ASYNCHRON)


activated

At open DCM die, the plunger is once fully


moved forward and back into end position.

Instruction for MANUAL DOSING:


- CLOSE DCM-DIE in position MANUAL!
completely !
MODIFY
INFO
DATA
DOSING

OFFLINE:
7.65kg
DOS. PIPE: 80/24mm

t6

t7

AUTO
DOSING
SCAN=CELL ... ON

t8

DCM-DIE

DCM die is open.

t9

DC

TS=

PROCESSES and VISUALISATION


t2

The display field of the P ro D os DPC shows the


processes of the DCM die and the dosing process.
DCM die - Process sequence according to interface
signals:

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

Plunger in back position (I-24 = 1)

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING

t6

t7

t8

DCM-DIE

t6

t7

t8

DCM-DIE

WESTOMAT ProDos DPC


OPERATING MANUAL

t7

t6

Version: 03.00 A

t8

t7

t6

DOSING
0201-B.doc

DOSING CONTROL

t6

OPERATIONAL FUNCTIONS

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


position

DCM-DIE

Form closed (I-20 + I-21 = 1) and plunger in


back position

Die ready for injection (I-22 + I-23 = 1) and


plunger in back position

t8

DCM-DIE

OFFLINE:
7.65kg
DOS. PIPE: 80/24mm
t6

AUTO
DOSING
SCAN=CELL ... ON

DOSING MODE - Sequence of programme steps in


AUTO-SYNCHRON operation in connection with
closing process of DCM die:

t8

t7

The DCM die is ready for injection and the


P ro D os DPC is properly set to AUTO dosing
mode

P ro D os DPC signals to DCM control:


METAL FEED to AUTO - O-09 and DOSING
ON - O-14 = 1

Furnace chamber pressure


pressure hold for TOP-STOP

Lamps READY - O-22 = 1

DCM-DIE
TS=

t9
t1

DC

t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING

t6

t7

t8
t9

TS=
t1

DCM-DIE

DC

t2

t3

p= 29.12 mb

nc= 6379

02.01

DCM-DIE

t8

t7

3 - 10

t4

t5

ac=

below

the

The synchron. time t1 and the die closing


process = DIE CLOSES (I-19 = 1) start
simultaneously

ATTENTION
p = current furnace chamber pressure
nc = NOMINAL counter of dosing volume
ac = ACTUAL counter of dosing volume

The synchron. time t1 has expired and the


t6

pressure ramp to DC (R-DC/TS ) is initiated in the


furnace chamber, starting at the TOP-STOP
pressure hold level:

t8

t7

DCM-DIE
TS=

t9
t1

t2

nc= 6379

t4

DOSING ... RUN

t5

ac=

t6

DCM-DIE
t9
t1

t2

p= 29.82 mb

DC
t3

nc= 6379

t4

ac=

t5

Lamp DOSING OPERATION - O-23 = from 0


to 1

Pressure ramp to DC, signal = DIE CLOSED (I20 and I-21 = 1) - release of melt to shot sleeve

t8

t7

TS=

Cycle time t1 recorded

Dosing status from DOSING ... ON to


t3

p= 29.82 mb

DC

DCM cycle time t6 recorded

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING
02.01

4 - 10

0201-B.doc

Version: 03.00 A

At DC, pressure ramp to DOSING (R-DOS), start


of metal feed and calculation of ACTUAL
counter value for dosing volume:
Cycle times t2 and t9 recorded

P ro D os DPC signal to DCM


METAL FEED - O-10 = from 0 to 1

t8

t7

DCM-DIE
TS=

t6

DOSING CONTROL

t9
t1

control

DC

t2

t3

p= 39.32 mb

nc= 6379

t4

t5

ac=

if DC with electrode, it is moved upwards

During feed pressure rise (or during feed time),


the signals for DIE READY FOR INJECTION (I22 and I-23 = 1) are received, release of melt
for dosing to shot sleeve, DCM awaiting
RELEASE FOR INJECTION:

DCM cycle time t7 recorded

Feed pressure reached = stop of pressure rise


and feed presser holding:

Cycle time t3 recorded

Start of lag time

Metal feed with max. pressure

t6

t8

t7

DCM-DIE
TS=

t9
t1

DC

t2

t3

p= 75.42 mb

nc= 6379

t6

t4

t5

ac=

t8

t7

DCM-DIE
TS=

When ACTUAL counter = NOMINAL counter,


start of deaeration (release of furnace chamber
pressure):

Cycle time t4 recorded

Lag time t5 and DC monitoring time t5 -DC


started

ACTUAL counter continued until end of


metal feed

t9
t1

t2

The furnace chamber pressure is reduced

Test of DC after deaeration has been


carried out and t5-DC is completed

t3

p= 99.42 mb

nc= 6379

t6

t9

ac=

DC

t2

t3

p= 99.37 mb

nc= 6379

t6

t4

t5

ac=

t8

t7

DOSING ... END


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

t5

t8

t7

TS=

Dosing status from DOSING ... RUN to

t4

DCM-DIE

t1

Lag time t5 has expired and the dosing process


is completed. ACTUAL counter is stopped:

DC

DCM-DIE
TS=

t9
t1

t2

p= 27.82 mb

DC
t3

nc= 6379

t4

t5

ac=6867

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING
0201-B.doc

DOSING CONTROL

t6

OPERATIONAL FUNCTIONS

Version: 03.00 A

t8

t7

DCM-DIE
TS=

t9
t1

DC

t2

t3

p= 17.34 mb

nc= 6379

t4

t5

02.01

Signal to DCM control = RELEASE OF


INJECTION - O-11 and O-12 = 1:

Signal READY FOR INJECTION - I-22


and I-23 = 0

PLUNGER starts to move, I-24 = 0

ac=6867

The plunger movement is carried out while the


cast solidifies, etc. In the furnace chamber, the
holding pressure for TOP-STOP is built up

The

furnace
reached:

t6

5 - 10

pressure

TOP-STOP-hold

is

t8

t7

DCM-DIE
TS=

t9
t1

DC

t2

t3

p= 29.84 mb

nc= 6379

t6

t4

t5

ac=6867

After solidification, the DCM die is opened, the


cast is removed and the die is prepared for new
cycle

Plunger returns to back position - I-24 = from 0


to 1:

t8

t7

DCM-DIE
TS=

t9
t1

DC

t2

t3

p= 29.84 mb

nc= 6379

t4

t5

ac=6867

Dosing status from DOSING ... END to


DOSING ... ON
t6

t8

t7

DCM-DIE
TS=

t9
t1

Dosing cycle is completed

DOSING OPERATION lamp - O-23 = from 0


to 1 and WESTOMAT ready for next dosing
cycle

The following closing movement (I-19 = from


0 to 1) starts the next dosing cycle and the
total cycle time (t-CYCL) of the previous
cycle is recorded.

DC

t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT

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

t6

t7

t8

DCM-DIE
t9

DC

TS=

t2

p= 27.82 mb

t3

nc= 6379

t4

t5

ac=6867

the

The procedure is similar to that of the


SYNCHRON cycle, apart from the dosing
pressure ramp to DC (R -DC/TS ), which starts
from the pressure level TOP-STOP holding
after competed closing of DCM-die (I-19 to I23 = 1).

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING
02.01

6 - 10

0201-B.doc

MANUAL dosing mode:

Manual dosing is started by pressing key F5


at manual closing of DCM-die (I-19 toI-24 =
1).

Version: 03.00 A

DOSING CONTROL

OFFLINE:
7.65kg
MANUAL
DOSING
SCAN=CELL ... ON
DOS. PIPE: 80/24mm
DOSING by HAND = READY
t6

t7

DCM-DIE

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
DOSING
INFO
DATA
by HAND

Visualization of process as above and without


synchron. time t1.

OFFLINE:
7.65kg
DOS. PIPE: 80/24mm
t6

t7

DCM-DIE

TS=

DC
t2

DOSING PROCESS in WESTOMAT


with TOP-STOP
The dosing process in the furnace consists of the
following steps:

PRESSURE START to DOSING CONTACT (DC):

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

DOSING CONTACT (DC) with:

NOMINAL counter of dosing volume - calculated


from
OPERATING-kg-DIAGRAM
for
the
respective dosing pipe - is set

Start of calculation of ACTUAL counter value for


the dosed volume

Measuring of furnace pressure P -DC/TS

Measuring of rising time of melt to DC = t2

PRESSURE RISE to FEED PRESSURE (P-FD):

with PRESSURE RAMP AFTER DC (R-after DC)


- see set value in LOG K17 = dosing pipe 1 or
K18 = dosing pipe 2

MANUAL
DOSING
SCAN=CELL ... RUN

t3

p= 99.37 mb

nc= 6379

INFO

MODIFY
DATA

t4

t5

ac=
DOSING
by HAND

OPERATIONAL FUNCTIONS

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING
0201-B.doc

DOSING CONTROL

Version: 03.00 A

7 - 10

02.01

FEED PRESSURE (P-FD) REACHED:

P-FD - for value see LOG K06

Start with dosing volume


OPERATING-kg-DIAGRAM

calculated

from

ACTUAL counter = NOMINAL counter (AC = NC):

Deaeration (reduction of furnace


pressure) to pressure level P -DEAE

Start of time t-DEAE

chamber

Start of DC verification time after deaeration (t5 DC )

Start of t5 = lag time - for value see kg-DOS:

A = PRESSURE START

DC = DOSING CONTACT

B = FEED PRESSURE REACHED

C = ACTUAL counter = NOMINAL counter

D = DC VERIFICATION (I-01 = 0)

E = END DOSING CYCLE

F = TOP-STOP reached

NEW or MODIFY DATA

mbar

t5 = LAG TIME COMPLETED:

DC verification after t 5-DC negative - dosing


cycle END

Rise to TOP -STOP holding pressure = **.*


mbar below P-DC - for value see LOG K06

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

R - after DC

P-FD

R -DC/TS

DC

P (TOP-STOP)
F

P -DC/TS
P -TS

P -TS
P -DEAE
t -DEAE
t -ADJ

NC= NOM. COUNTER

sec
D

AC = ACT. COUNTER

E
t5-DC

t2

t3

t4

t5

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING
02.01

8 - 10

0201-B.doc

Version: 03.00 A

DOSING CONTROL

DOSING PROCESS in WESTOMAT


without TOP-STOP

mbar

R - after DC

R -DC

P -FD
DC
P -DC

0.0 mbar

t -DEAE
NC = NOM. COUNTER

sec
A

AC = ACT. COUNTER

E
t5-DC

t2

t3

t5

t4

The dosing process in the furnace consists of the


following steps:

A = PRESSURE START

DC = DOSING CONTACT

PRESSURE START to DOSING CONTACT (DC):

B = FEED PRESSURE REACHED

C = ACTUAL counter = NOMINAL counter

D = DC VERIFICATION (I-01 = 0)

E = END DOSING CYCLE

Pressure ram R-DC - for value see LOG K08

DOSING CONTACT (DC) with:

NOMINAL counter (with partial correction) of


dosing volume - calculated from OPERATINGkg-DIAGRAM for the respective dosing pipe - is
set

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

DOSING
0201-B.doc

Version: 03.00 A

02.01

Start of calculation of ACTUAL counter value for


the dosed volume

Measuring of furnace pressure P -DC

Measuring of rising time of melt to DC = t2

PRESSURE RISE to FEED PRESSURE (P-FD):

9 - 10

with PRESSURE RAMP AFTER DC (R-after DC)


- for value see LOG K17 = dosing pipe 1 or K18
= dosing pipe 2

FEED PRESSURE (P-FD) REACHED:

P-FD - for value see LOG K06

Start with dosing volume


OPERATING-kg-DIAGRAM

calculated

from

ACTUAL counter = NOMINAL counter

Deaeration - pressure release from furnace


chamber

Start of time t-DEAE

Start of DC verification time after deaeration (t5 DC )

Start of t5 = lag time - for value see kg-DOS:


NEW or MODIFY DATA

t5 = LAG TIME COMPLETED:

DC verification after t 5-DC negative - dosing


cycle END

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING
02.01

10 - 10

0201-B.doc

blank page

Version: 03.00 A

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS
DOSING
02011-A.doc

Version: 12.99 A

1-4

DOSING VOLUME (DATA SHEET)

02.01.1

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


of the Pro Dos DPC, the user-specific dosing range
(from smallest to largest dosing volume in kg) is
entered and saved.
For DOSING, the required dosing volume is entered as
a kg value in the kg-DOS file and saved. The dosing
volume can be adjusted at a later stage, if required,
see chapter 02.01.2.
A kg-DOS file contains the following parameters:
21.07.99 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
, INPUT, ENTER, MEMO / ESC=back
kg-DOS-RANGE:

2.50 to 8.35 kg

5.75 kg = dosing volume (OFFLINE)


+0.30
kg = AUTO-increase up to 0.75
-0.25
kg = AUTO-decrease up to 0.75
-28.0
% = furnace chamber-CORRECTION
1.7
s = t5 - lag time
P-FD = 60 mbar / t4 = 0.75 s
INFO

5.75 kg .................................. Dosing volume

+ 0.30 kg .................................. AUTO-increase

0.25 kg .................................... AUTO-reduction

28.0

% ................ Furn. chamb.-CORRECTION

- 32.0 % .................. .. Counter-CORRECTION,


not displayed in this menu

1.7

s .......................................... Lag time

P-FD = 60 mbar ............................. Feed pressure

t4 = 0.75 s .......................................... Feed time

DOSING VOLUME

Die-specific dosing quantity in kg (max. 2


decimals):

the kg value must be entered in the menu for


kg-DOS: NEW and MODIFY DATA.

The display shows the operator-specific


dosing volume range as a guideline for the
kg values

The feed volume can deviate by approx.


5% from the nominal value.

AUTO-INCREASE

Die-specific quantity in kg (max. 2 decimals) of


dosing volume increase:

The dosing volume increase is used for dies


with
additional
inlets
during
dosing
processes where these inlets are not used

The dosing volume increase is activated


automatically via the DCM interface

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME (DATA SHEET)


02.01.1

2-4

02011-A.doc

AUTO-INCREASE (cont.)

the kg value must be entered in the menu for


kg-DOS: NEW and MODIFY DATA.

There is a limit regarding the new value as it


is related to the nominal value of the kgDOSING VOLUME.

This restriction is indicated in the display as


a limit value.

AUTO-REDUCTION

Die-specific quantity in kg (max. 2 decimals) of


dosing volume reduction:

The dosing volume reduction is used in


dosing processes, that are carried out
without DCM pressing process. It prevents
the increase of sprue.

The dosing volume reduction is activated


automatically via the DCM interface

the kg value must be entered in the menu for


kg-DOS: NEW and MODIFY DATA.

There are restrictions regarding the new


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

This restriction is indicated in the display as


a limit value.

FURNACE-CHAMBER-CORRECTION

%-value (1 to 99, without decimals) of the


dosing volume correction, which compensates
for the furnace-specific gradual reduction in
dosing volumes that occurs when the furnace is
being emptied:

the kg value must be entered in the menu for


kg-DOS: NEW and MODIFY DATA.

The entry of an insufficient % value results in


a continuous reduction in the dosing volume
as the furnace is being emptied

The entry of a % value that is too high


results in a continuous increase in the
dosing volume as the furnace is being
emptied

There are restrictions regarding the new


value as it is related to the nominal % value.

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME (DATA SHEET)


02011-A.doc

Version: 12.99 A

02.01.1

COUNTER-CORRECTION

3-4

%-value (1 to 99, without decimals) of the


dosing volume correction, which compensates
for the system-specific gradual increase in the
number of dosing processes that occurs when
the furnace chamber pressure is being reduced:
The counter correction is automatically
activated if the furnace chamber is not under
pressure at the time of PRESSURE START
for dosing

By activating this correction, the NOMINAL


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

The % value is entered and modified in the


LOG set-up mode

The entry of an insufficient % value results in


an increase of the dosing volumes

The entry of a % value that is too high


results in a reduction of the dosing volumes.

LAG TIME

Dosing process time in seconds with one


decimal; time from the start of the pressure
reduction in the furnace chamber (END of metal
feed) until all melt has been poured into the
shot sleeve:

The sec value must be entered in the menu


for kg-DOS: NEW and MODIFY DATA.

There are restrictions regarding the new


value as it is related to the nominal sec
value.

The entry of an insufficient sec value results


in the dripping of the melt onto the plunger

The entry of a sec value that is too high


results in a prolonged total cycle time for the
cast.

FEED PRESSURE and FEED TIME

The parameters for feed pressure (P-FD) and


feed time (t4) are automatically recalculated and
displayed upon the entry of a kg value:

The operator cannot directly enter the values


of these parameters.

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME (DATA SHEET)


02.01.1

4-4

02011-A.doc

blank page

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS
DOSING
02012-B.doc

Version: 03.00 A

1-6

DOSING VOLUME - NEW / CORRECTION

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

02.01.2

At each change of tools, the die-specific dosing


volume and other parameters of the DOSING VOLUME
file must be entered:

these modifications are made in the kg-DOS NEW


menu.

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

AVAILABLE = 890 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

If the dosing volume or any of the parameters of the


kg-DOS VOLUME file are altered, the respective data
must be modified:

these modifications are made in the menu


MODIFY DATA.

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

F1

F2

F3

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

F4

F5

10.03.00
13:34:57

multi-function key

HEATING
SCAN=CELL
=
PIPE
SELECTION,
ENTER
/
ESC=back

65 /21 mm NO 1 = DOSING PIPE

The display changes to entry status or dosing


pipe selection status:

SELECTION DOSING PIPE


80 /24 mm NO 1 = DOSING PIPE

F4

The dosing pipe selection status allows for


the selection of the respective dosing pipe. It
is only activated if two different dosing pipes
have been entered in the LOG.

Press

INFO

10.03.00
HEATING
OFFLINE: kg-DOS-NEW
13:34:57
SCAN=CELL
DOS. PIPE 65/21mm
=
PIPE
SELECTION,
ENTER
/
ESC=back

or
pipe line

to place cursor in dosing

and press key

SELECTION DOSING PIPE


65 /21 mm NO 1 = DOSING PIPE
80 /24 NO 1 = DOSING PIPE

INFO

10.03.00 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
, INPUT, ENTER and MEMO / ESC=back
kg-DOS-RANGE:

2.50 to 7.35 kg

3.55
kg = dosing volume (OFFLINE)
+0.00
kg = AUTO-increase up to 4.27
0.00
kg = AUTO-decrease up to 3.25
28.0
% = furnace chamber-CORRECTION
1.7
s = t5 - lag time
P-FD = 60 mbar / t4 = 0.85 s
INFO

The display changes to kg-DOS entry status:


NEW, and the following values are displayed
(see also chapter 02.01.1):
- Dosing volume range
- The previously entered dosing volume and
the NEW dosing volume must be entered
- The values for AUTO-INCREASE and
REDUCTION are reset to 0.0 and must be
re-entered, if necessary
- The previously entered value of the furnace
chamber
CORRECTION
must
be
transferred
- The previously entered T5 lag time must
be transferred
- The values for P -FD and t4 correspond to
the previously entered dosing volume and
are recalculated for the NEW entry.

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME NEW / CORRECTION


2-6

02.01.2

02012-B.doc

EXAMPLE OF ENTRY (kg-DOS: NEW)

5.7 kg is the NEW, die-specific dosing volume


to be entered:

Version: 03.00 A

and continue

DOSING CONTROL

10.03.00 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 SCAN=CELL
DOS. PIPE:65/21mm
,
INPUT,
ENTER
and
MEMO / ESC=back

kg-DOS-RANGE:

WESTOMAT P ro Dos DPC


OPERATING MANUAL

5.70

2.50 to 7.35 kg

kg = dosing volume (OFFLINE)

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


sec are recalculated and automatically
displayed

ATTENTION
Entered values that are not within the dosing
value range (here between 2.5 and 7.35) are
rejected as TOO HIGH / TOO SMALL.

As in this example, the new die is to be used


without inserts, and entry for AUTO-INCREASE
is not necessary:
- Continue with

+0.00

kg = AUTO-increase

up to 0.57

-0.30

kg = AUTO-decrease up to 0.57

The tool to remove cast from die grasps the cast


at the sprue. Excessive sprues may result in
disturbances; the pressing processes are
signalled to the unit via DCM interface.
- Enter 0.3 kg (recommended value) for AUTOREDUCTION

and continue

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

The set value for the furnace chamberCORRECTION (28%) is based on many years of
experience. It ensures that the dosing volume
remains constant while the furnace is gradually
emptied. This value should not be altered.
- Continue with

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


based on many years of experience. As the
dosing channel length and inclination have not
been changed in this example, the values must
not be altered.

28.0

% = furnace chamber-CORRECTION

1.7

s = t5 - lag time

- Continue with

ATTENTION
For the furnace chamber-CORRECTION and the
t5 LAG TIME, enter real numbers (not 0). Higher
values are rejected as TOO HIGH.

P-FD = 60 mbar / t4 = 1.29 s


INFO

OPERATIONAL FUNCTIONS
DOSING

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING VOLUME NEW / CORRECTION


02012-B.doc

DOSING CONTROL

Version: 03.00 A

3-6

10.03.00 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 SCAN=CELL
DOS. PIPE:65/21mm
ATTENTION: DATA HAVE BEEN MODIFIED!

After entry and pressing of key

F1 - SAVE DATA MODIFICATION

the LED of the MEMO key is blinking (ready to


save):

F3 DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

Save entered data:

MEMO =
NO

F1

F2

press MEMO key; the display


changes to saving mode; continue with

F5 - BACK TO ENTRY
MEMO
= YES

02.01.2

BACK TO
ENTRY

F3

F4

F1

MEMORY = YES:

The new values are saved

F5

F3

MEMORY = NO:

The new values are deleted and the previous


values remain saved; the display returns to
initial status

F5

BACK TO ENTRY:

The previous values are not overwritten; the


display returns to the entry form, where the
newly entered values are displayed;
additional entries and modifications can be
made.
The entry of a NEW kg-DOS-VOLUME file is
completed.

MODIFY DATA
OFFLINE:
5.60kg
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE: 65/21mm
EXT-KEY DOS-ON /instruction/ ESC=back

To modify a parameter of an existing kg-DOS VOLUME


file, proceed as follows:

To DOSING by HAND:
DCM-DIE = READY FOR DOSING!
INFO

MODIFY
DATA

kg-DOS:

NEW

DOSING

F4

F5

in F5 STATUS, use multifunction key

F1

F2

F3

OFFLINE:
5.60kg
DOS. PIPE: 65/21mm
t6

AUTO
DOSING
SCAN=CELL ... ON

F3

= MODIFY DATA or

In DOSING STATUS, press

t8

t7

DCM-DIE
TS=

t9
t1

t2

DC
t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING
multi-function key

F1

F2

F3

F4

F5

F3

= MODIFY DATA or

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME NEW / CORRECTION


4-6

02.01.2

02012-B.doc

EXAMPLE OF ENTRY (MODIFY DATA)


The dosing results are too small by approx. 0.3 kg
and are further gradually reduced by 0.2 kg as the
furnace is being emptied.
The existing kg-DOS VOLUME file must be
adjusted:
- Dosing volume - from 5.6 to 5.9 kg
- Furnace chamber-CORRECTION - from 28 to
33%
The control is in AUTO-DOS mode and the
MODIFY DATA status has been activated.

Enter NEW dosing volume: 5.9 kg

and continue

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

OFFLINE:
5.60kg
AUTO
DOSING
SCAN=CELL ... ON
DOS. PIPE: 65/21mm
, INPUT, ENTER and MEMO / ESC=back
kg-DOS-RANGE:

4.53 to 6.67 kg

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

kg-DOS-RANGE:
5.90

4.53 to 6.67 kg

kg = dosing volume (OFFLINE)

- The values for P -FD = 60 mbar and t4 = 1.49


sec are recalculated and automatically
displayed.

ATTENTION
Entered values that are not within the dosing
value range (here between 4.53 and 6.67) are
rejected as TOO HIGH / TOO SMALL.

In this example, the die is to be used without


inserts and an entry for AUTO-INCREASE is not
necessary:

+0.00

kg = AUTO-increase

up to 0.56

-0.30

kg = AUTO-decrease up to 0.56

- Continue with

AUTO-REDUCTION is carried out correctly a


modification is not necessary:
- Continue with

Due to the dosing volume reduction that results


from the furnace being gradually emptied, the %
value of the furnace chamber-CORRECTION
must be increased accordingly:
- Enter 33 % (recommended value)

and continue

The value for t5-LAG TIME (1.7 sec) is based on


many years of experience and must not be
modified.

33.0

% = furnace chamber-CORRECTION

1.7

s = t5 - lag time

- Continue with

ATTENTION
For the furnace chamber-CORRECTION and the
t5-LAG TIME, enter real numbers (not 0).
Correction is only possible up to a certain
extent. Values that exceed this limit are rejected
as TOO HIGH.

P-FD = 60 mbar / t4 = 1.49 s

OPERATIONAL FUNCTIONS
DOSING

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING VOLUME NEW / CORRECTION


02012-B.doc

DOSING CONTROL

Version: 03.00 A

5-6

OFFLINE:
5.60kg
AUTO
DOSING
SCAN=CELL ... ON
DOS. PIPE: 65/21mm
ATTENTION: DATA HAVE BEEN MODIFIED!

After entry and pressing of key

F1 - SAVE DATA MODIFICATION

F3 DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

the LED of the MEMO key is blinking (ready to


save):
Save entered data:

F5 - BACK TO ENTRY
MEMO
= YES

02.01.2

press MEMO key; the display


changes to saving mode; continue with

MEMO =
NO

BACK TO
ENTRY

F1

MEMORY = YES:

The new values are saved

F1

F2

F3

F4

F5

F3

MEMORY = NO:

The new values are deleted and the previous


values remain saved; the display returns to
initial status

F5

BACK TO ENTRY:

The previous values are not overwritten; the


display returns to the entry form, where the
newly entered values are displayed;
additional entries and modifications can be
made.

ATTENTION
OFFLINE:
5.90kg
DOS. PIPE 65/21mm
t6

AUTO
DOSING
SCAN=CELL ... ON

The data is saved as usual, but apply only to the


next dosing cycle.

t8

t7

DCM-DIE
TS=

t9
t1

t2

The above data can be corrected at any time by


means of MODIFY DATA without interruption of
the dosing process.

DC
t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING

The entry of a NEW kg-DOS-VOLUME file is now


completed.

OPERATIONAL FUNCTIONS
DOSING

DOSING VOLUME NEW / CORRECTION


02.01.2

6-6

02012-B.doc

blank page

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

0202-A.doc

Version: 12.99 A

INTERFACE: WESTOMAT - DCM

1 / 12

02.02

The controls of the die-casting machine (DCM) and the


WESTOMAT with the Pro Dos DPC are connected
via an interface. This interface is designed according
to the highest safety standards of the die-casting
industry and coordinates all processes.
The signal interface processes the following signals:

From DCM to WESTOMAT = input signals to the


Pro Dos DPC:

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


auto-operation ON .................................. I-18
die closes .............................................. I-19
die closed 1 ........................................... I-20
die closed 2 (optional) .......................... I-21
die ready for injection 1 .......................... I-22
die ready for injection 2 (optional) ........... I-23
plunger in back position .......................... I-24
discontinue synchro. operation (optional).. I-25
kg-reduction (optional) ........................... I-26
kg-increase (optional) ............................. I-27

From WESTOMAT to DCM = output signals of


Pro Dos DPC:

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


metal filling in (optional) ........................ O-10
release for injection 1 ............................ O-11
Release for injection 2 (optional) ............ O-12
disturbance metal supply ....................... O-13
ready for dosing ON ............................. O-14

In addition to the above signals, the controls are also


interconnected
as
regards
the
mandatory
EMERGENCY-STOP. The power supply part of the
WESTOMAT HEATING control is not connected to
the EMERGENCY STOP.
The switching status of the DCM signals corresponds
to the logical machine processes. The interface
request by the ProDos DPC takes into consideration
these logical machine processes. In the event of
discrepancies, dosing is halted, while a DCM position
error warning is issued. Alternatively, the dosing is
interrupted and an DCM ERROR MESSAGE is issued.
A WESTOMAT dosing operation is only possible if
the signal exchange with the DCM is properly
established.
The signals are designed as floating interrupters at a
signal voltage of 24 V DC.
Certain die-casting machines are equipped with
standard optional functions that are integrated in the
interface signalling system. These signals are labelled
as optional in this description.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

INTERFACE: WESTOMAT - DCM


0202-A.doc

2 / 12

02.02

Version: 12.99 A

DOSING CONTROL

CHARACTERISTICS OF INPUT SIGNALS

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


This signal is used by certain die-casting machines
for a fill test of the DCM die, i.e. for the testing of
the dosing volume and switching thresholds of the
end position of the plunger.
Requirements for the optional DCM function AUTO
FILL TEST:

Complete WESTOMAT control functions until


status MANUAL DOSING ... ON continue to
READY FOR DOSING, O-14 = 1
Close DCM die completely in status MANUAL
By parallel switching of the signals I-17 and I18 = from 0 to 1, a single AUTO DOSING
process is carried out. See flow diagram.

OFFLINE:
27.65kg
MANUAL
DOSING
SCAN=CELL ... ON
DOS. PIPE: 100/24mm
DOSING by HAND = READY
t6

t7

DCM-DIE

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO
MODIFY
MANUAL
DATA
by HAND

FLOW DIAGRAM: AUTO-FILL TEST

from DCM to
WESTOMAT:

I-17
I-18
I-19
I-20 + 21
I-22 + 23
I-24
I-25
I-26
I-27

Switching DOS-ON .................


MANUAL DOSING ... END
MANUAL DOSING ... ON ...
DOSING CONTACT ................
AUTO DOSING ... RUN .......
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I17 = 0 is checked and, if incorrect, position error I17 = 1 is signalled.

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


0202-A.doc

Version: 12.99 A

OFFLINE:
5.75kg
MANUAL
DOSING
SCAN=CELL ... END
DOS. PIPE: 80/24mm
instruction / EXT.-KEY DOS-OFF
Instruction for AUTO-DOSING:
- Set DCM into AUTO !
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL!
completely !
MODIFY
INFO
DATA
DOSING
OFFLINE:
27.65kg
DOS. PIPE: 100/35mm
_

AUTO
DOSING
SCAN=CELL ... ON

3 / 12

02.02

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


If the DCM is in -AUTO and AUTO mode, the signal
switches to I-18 = 1. The Pro Dos DPC is switched
from MANUAL mode to AUTO-DOS mode.
The switching to AUTO must be started from MANUAL
mode of the DCM control:

while DCM die is open


Set Pro Dos DPC to DOSING mode (advance
and retract plunger once) and continue to
operate according to instructions AUTOMANUAL
Set DCM control to -AUTO or AUTO mode:

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA

The signal METAL FEED TO AUTO, O-09


switches from 0 to 1.

FLOW DIAGRAM: Start AUTO-DOS

I-17
I-18
I-19

from DCM to
WESTOMAT:

I-20 + 21
I-22 + 23
I-24
I-25
I-26
I-27

Switching DOS-ON .................


MANUAL DOSING .. END..
AUTO DOSING .. ON .........
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I18 = 0 is checked and, if incorrect, position error I18 = 1 is signalled.
A switching to AUTO mode at an earlier stage is
not possible and the Pro Dos DPC issues position
error I-18 = 1.
During dosing operation AUTO DOSING ... RUN,
the switch position I-18 = 1 is monitored: if I-18 =
from 1 to 0, dosing is interrupted and DCM
DISTURBANCE is signalled.

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


4 / 12

02.02

0202-A.doc

Version: 12.99 A

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


This signal switches in MANUAL, -AUTO and
AUTO mode of the DCM. as follows: I-19 = from 0 to
1, if the closing of the movable die plate is started.
In MANUAL DOSING mode, I-19 is only queried in
the process of the logical switching sequence of the
signalled closing movement of the DCM die.
In AUTO DOSING mode, the switching of I-19 =
from 0 to 1 initiates the following:

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


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

initiation

of

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I19 = 0 is checked and, if incorrect, position error I19 = 1 is signalled.
The signalling of the start of movement of the die
plate is important in order to maintain the repeated
accuracy of the closing time (t 6) of below 0.25
sec.
During dosing operation AUTO DOSING ... RUN,
the switching position I-19 = 1 is monitored: if I-19
= from 1 to 0 after PRESSURE START and if I-20 /
21 = 0, dosing is interrupted and DCM
DISTURBANCE is signalled.

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


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

If the normal dosing volume in used in such a


case, the sprue is reduced accordingly.

The Pro Dos DPC automatically takes this increase


into account, if I-27 = from 0 to 1 prior to the start of
the die closing (I-19 to I-23 = 0).
ATTENTION
In addition to the function of dosing volume
INCREASE, I-27 = from 0 to 1 discontinues AUTOsynchronization for the next two process steps
(similar to I-25).

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


0202-A.doc

Version: 12.99 A

5 / 12

02.02

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


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

..

The signals switch in MANUAL, -AUTO and AUTO


mode of the DCM.I-20 and 21 = from 0 to 1, when the
die plates are adjacent during the closing movement,
i.e. when the shot sleeve is closed at the front.

For reasons of safety, the closing status of the DCM


die is signalled via two separate channels: hardware
with software query, and hardware only.
In MANUAL DOSING mode, I-20 and I-21 are only
queried in the process of the logical switching
sequence of the signalled closing movement of the
DCM die.
In AUTO DOSING mode, the switching of I-20 / 21 =
from 0 to 1 initiates the following:

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


is completed (repeatable accuracy of this time is
less than 0.25 sec):

in AUTO-SYNCHRON operation (with DCMDIE CLOSED) = release of metal feed to


shot sleeve

Measuring of closing time (t 7) of the DCM die


is started.

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I20 / 21 = 0 is checked and, if incorrect, position
error I-20 / 21 = 1 is signalled.
During dosing operation AUTO DOSING ... RUN,
the switch position I-20 / 21 = 1 is monitored, and
if:

At DC = start of metal feed I-20 / 21 = 0, dosing is


interrupted and DISTURBANCE DC BEFORE
DCM-DIE CLOSED is signalled.

If, after PRESSURE START, I-20/21 = from 1 to 0


and I-22 / 23 = 0, dosing is interrupted and
DISTURBANCE DCM is signalled.

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


6 / 12

02.02

0202-A.doc

Version: 12.99 A

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


DIE READY FOR INJECTION 2 (OPTIONAL) I-23
The signals switch in MANUAL, -AUTO and AUTO
mode of the DCM. I-22 and 23 = from 0 to 1, if the
closing section of the DCM is locked at the closing
movement.
For reasons of safety, the closing status of the
DCM die is signalled via two separate channels,
e.g. hardware with software query, and hardware
only.
In MANUAL DOSING mode, I-22 and I-23 are
queried prior to release.
In AUTO DOSING mode, the switching of I-22 / 23
= from 1 to 1 initiates the following:

Measuring of t 7 of the DCM closing time is


completed. The repeatable accuracy of this time
is between 0.5 and 2.5 sec:

In AUTO-ASYNCHRON
START for dosing

In AUTO-SYNCHRON (with DCM-DIE


CLOSED) = release for continued injection

In AUTO-SYNCHRON operation (with DCMDIE READY FOR INJECTION) = release of


metal feed to shot sleeve

PRESSURE

Measuring of t 8, injection stop time (from DCM


die ready for injection to release) is started

After
DOSING
END,
RELEASE
FOR
INJECTION 1 / 2 are only completed, if I-22 / I23 = 1

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I22 / 23 = 0 is checked and, if incorrect, position
error I-22 / 23 = 1 is signalled.
During dosing operations MANUAL and AUTO
DOSING RUN, the switching positions I-22 / I23= 1 are monitored: if I-22 / I-23 = from 1 to 0,
dosing is interrupted and DCM DISTURBANCE is
signalled.

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


0202-A.doc

Version: 12.99 A

7 / 12

02.02

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


This signal switches in MANUAL, -AUTO and
AUTO mode of the DCM. I-24 = from 0 to 1, if the
plunger has reached the back position.
In DOSING MODE and in F5 STATUS, the switch
positions I-19 to I-24 = 0 are checked after each
DOSING operation, or after a disturbance in the
DOSING operation. From this status the release of
the next DOSING operation is initiated by means of
switching I-24 = from 0 to 1:

At completely opened DCM die, the plunger is


once advanced and retracted fully (check of
shot sleeve content).

ATTENTION
After starting the Pro Dos DPC from BASIC
STATUS to DOSING MODE, the switching status I24 = 0 is checked and, if incorrect, position error I24 = 1 is signalled.
During dosing operations MANUAL and AUTO
DOSING RUN, the switching position I-24 = 1 is
monitored: if I-24 = from 1 to 0, dosing is
interrupted and DCM DISTURBANCE is signalled.
After RELEASE OF INJECTION 1 / 2, the switching
of I-24 = from 1 to 0 (approx. 20 sec) is checked. if
not switched, a DCM DISTURBANCE is signalled.

kg-REDUCTION (OPTIONAL) ...................... I-26


This signal switches in MANUAL, -AUTO and
AUTO mode of the DCM. I-26 = from 0 to 1, if the
impact force of the plunger is considerably reduced
(e.g. without final stage), during the current DCM
cycle:

If the normal dosing volume in used in such a


case, the sprue is increased accordingly.

The Pro Dos DPC automatically takes this reduction


into account, if I-26 = from 0 to 1 prior to the start of
the die closing (I-19 to !-23 = 0).
ATTENTION
In addition to the function of dosing volume
REDUCTION, I-26 = from 0 to 1 discontinues
AUTO-synchronization for the next two process
steps (similar to I-25).

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM

0202-A.doc

8 / 12

02.02

DISCONT. SYNCHRO. OPERATION (OPT.) I-25


This signal switches in MANUAL, -AUTO and
AUTO mode of the DCM. The AUTO-synchronization
of the operating steps of the DCM and the
WESTOMAT is suspended for the next two cycles.
I-25 = from 0 to 1, if:

The closing movement of the DCM die is


interrupted and the die is automatically opened
(e.g. if force of closing part is too high or too
low):

In SYNCHRO. operation, up to 0.2 sec after


the signals are switched I-20 / 21 = from 0 to
1; in later switching sequences, the dosing
operation might be terminated, as a result of
DISTURBANCE DC BEFORE DCM-DIE
CLOSED

The following dosing cycle is initiated in


AUTO-ASYNCHRON, if the signals I-19 to I23 = from 0 to 1

Signals I-19 to I-23 = 0, and if the subsequent


closing of the DCM does not conform to the
standard closing procedure, e.g.
automatic
testing of the hydraulic tensioning device of the
die (quick tension test) or at first dosing cycle:

In these circumstances, the following


dosing cycle is initiated in AUTOASYNCHRON when closing is completed
and the signals I-19 to I-23 = from 0 to 1.

FLOW DIAGRAM: AUTO-SYNCHRON-DOS and I-25 = 1


I-17
I-18
I-19

from DCM to
WESTOMAT:

I-20 + 21
I-22 + 23
I-24
I-25
I-26
I-27

Switching DOS-ON .................


AUTO DOSING ... ON .........
AUTO DOSING ... RUN
DOSING CONTACT .................
AUTO DOSING ... END ......
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

ATTENTION
If the DCM die is completely and properly closed,
(I-19 to I-24 = 1), the switching of I-25 = from 0 to 1
is ignored.

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


0202-A.doc

Version: 12.99 A

9 / 12

02.02

CHARACTERISTICS OF OUTPUT SIGNALS

METAL FEED TO AUTO .............................. O-09


With signal O-09 = from 0 to 1, the Pro Dos DPC
confirms to the DCM control that the DCM
automatic control has been properly connected at
the start-up of the controls.
The WESTOMAT is ready for DOSING in AUTODOS mode:

A dosing operation is initiated by the


closing of the DCM die.

AUTO

Signal O-09 is switched from 1 to 0:

If DCM control is not in -AUTO or AUTO mode

If the Pro Dos DPC is not in DOSING mode

If the Pro Dos DPC is not ready for DOSING,


e.g. due to a position error for the DCM die

If the Pro Dos DPC is in DISTURBANCE


mode

ATTENTION
O-09 = 0 in conjunction with READY FOR DOSING
ON O-14 = 1 can be used as indicators for the DCM
operator on the readiness of the unit; see examples
for O-14.

METAL FEED ON (OPTIONAL) .................. O-10


In MANUAL and AUTO DOSING mode, the
Pro Dos DPC signals with O-10 = from 0 to 1 to
the DCM control that metal is feed to the shot
sleeve at dosing contact.
Signal O-10 is switched from 1 to 0:

automatically at the program stage DOSING


END

If the Pro Dos DPC is in DISTURBANCE


mode.

ATTENTION
This signal is for example used for the start of the
plunger cooling process.

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


02.02

10 / 12

0202-A.doc

RELEASE FOR INJECTION 1 .................... O-11


RELEASE FOR INJECTION 2 (OPTIONAL) O-12
With O-11 / 12 = from 0 to 1, the Pro Dos DPC
signals to the DCM control that the filling process of
the dosing volume into the shot sleeve is
completed and that the plunger can initiate the
pressing operation, provided that the machine is in
AUTO DOSING mode (or AUTO-fill test) and the
DCM die is READY FOR INJECTION (I-22 / 23 = 1):

Measuring of t 8, injection stop time (from DCM


die ready for injection to release) is started

Signals O-11 / 12 are switched from 1 to 0:

When the plunger has left the back position (for


pressing) after DOSING END

If the Pro Dos DPC is in DISTURBANCE


mode.

ATTENTION
For reasons of safety, the RELEASE FOR INJECTION
is signalled via two separate channels. The switching
(0 / 1 / 0) is synchronised at 0.5 sec.

DISTURBANCE METAL SUPPLY ............... O-13


With O-13 = from 0 to 1, the Pro Dos DPC signals
to the DCM control that the current MANUAL or
AUTO DOSING process has been interrupted due
to a relevant disturbance.
O-13 = from 0 to 1 is only used for the
communication by the ProDos DPC to the DCM
control for disturbances that have occurred in the
dosing cycle. In all other cases, the signals O-09
and O-14 = 0 are switched.
ATTENTION
In the event of disturbances, that are signalled to the
DCM control by means of O-13 = from 0 to 1, the DCM
operation is to be halted and it must be checked
whether there is melt in the shot sleeve.
It is not always necessary to switch off all of the other
DCM peripherals.
If there is melt in the shot sleeve:

allow melt to solidify

Switch DCM control to MANUAL

Retract DCM die

With the plunger, slowly press solidified (hot)


block from the shot sleeve and remove

Prepare shot sleeve and die for next injection


cycle

Find cause for disturbance and rectify.

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


0202-A.doc

Version: 12.99 A

11 / 12

02.02

READY FOR DOSING ON ......................... O-14


In MANUAL and AUTO DOSING mode, the
Pro Dos DPC signals with O-14 = from 0 to 1 to
the DCM control that DOSING mode has been
initiated.
At the first switching to DOSING mode, O-14 = from
0 to 1 is only signalled when the plunger is fully
advanced and retracted once (I-24 = from 0 to 1
and back) and if the DCM die is open (I-19 to I-23 =
0) - see switch diagram for initiation of AUTO
DOSING.
Signal O-14 is switched from 1 to 0:

If the Pro Dos DPC is not in DOSING mode

If the Pro Dos DPC is not ready for DOSING,


e.g. due to a position error for the DCM die.

If the Pro Dos DPC is in DISTURBANCE


mode

ATTENTION
At initiation of the DCM, the switch positions of O14 and O-09 can be used as indicators for the DCM
operator, e.g.:

DCM control in MANUAL mode and O-14 = 0


indicates:

METAL FEED NOT READY


METAL FEED = START DOS-ON AND
ADVANCE AND RETRACT PLUNGER
ONCE AT OPEN DCM DIE

The DCM control is switched from MANUAL to


-AUTO or AUTO mode and O-14 = from 1 to 0,
O-09 = 0 indicates:

METAL FEED NOT READY, OPEN DIE


AND INITIATE -AUTO OR AUTO MODE AT
OPEN DIE.

OPERATIONAL FUNCTIONS

INTERFACE: WESTOMAT - DCM


02.02

0202-A.doc

12 / 12

FLOW DIAGRAM: AUTO-SYNCHRON-DOS


I-17
I-18
I-19

from DCM to
WESTOMAT:

I-20 + 21
I-22 + 23
I-24
I-25
I-26
I-27

Switching DOS-ON .................


AUTO DOSING ... ON .........
AUTO DOSING ... RUN .......
DOSING CONTACT ..............
AUTO DOSING ... END ......
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

FLOW DIAGRAM: AUTO-SYNCHRON-DOS


I-17
I-18
I-19

from DCM to
WESTOMAT:

I-20 + 21
I-22 + 23
I-24
I-25
I-26
I-27

Switching DOS-ON .................


AUTO DOSING ... ON .........
AUTO DOSING ... RUN .......
DOSING CONTACT .............
AUTO DOSING ... END ......
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

FLOW DIAGRAM: MANUAL DOSING


I-17 + 18
I-19

from DCM to
WESTOMAT:

I-20 + 21
I-22 + 23
I-24
I-25
I-26 + 27

Switching DOS-ON .................


MANUAL DOSING ... END
MANUAL DOSING ... ON .
Press F5 = DOS-START ......
MANUAL DOSING ... RUN
DOSING CONTACT .............
O-09

from WESTOMAT
to DCM:

O-10
O-11 + 12
O-14

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

0203-B.doc

Version: 03.00 B

1/4

FURNACE FILLING LEVEL INDICATION

02.03

According to the specific equipment of the


WESTOMAT with the Pro Dos DPC, the furnace
filling level detection is carried out by means of:

HEATING
SCAN=HPDE
MANUAL
SCAN=HPDE

HEATING
SCAN=CELL
AUTO
SCAN=CELL

The Hydraulic-Pneumatic Pressure Detection


system (HPDE), indicated to the operator in the
display header as follows:

Displayed in basic status

Displayed in dosing mode

Selection / deactivation of the system is carried


out in the log (KO3). For basic settings, see
chapter 07.04.4

The load cell (CELL), indicated to the operator in


the display header as follows:

Displayed in basic status

Displayed in dosing mode

Selection / deactivation of the system is carried


out in the log (KO3 - see chapter 07.02).
Settings of the CELL (see chapter 07.04.3) and
the HPDE (see chapter 07.04.4).

ATTENTION
If a CELL is used and fails (or is disturbed), the
furnace filling level detection can be switched to the
HPDE system as follows:

K03. FURNACE FIL. LEVEL DETECTION WITH:


0
= (CELL = 1 / HPDE = 0)

Call up log (see chapter 07.02)

Activate HPDE in K03:


- for HPDE, enter 0 and save.
VISUALISATION
The furnace filling level is displayed by means of:

indicator lamps installed on the furnace:

three different options are available in display


mode of these indicator lamps (see chapter
07.04.1):

Mode 1: at FULL = all indicator lamps ON


Mode 2: at FULL = all indicator lamps OFF
Mode 3: Upper edge MELT SURFACE = only
one indicator lamp ON.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FURNACE FILLING LEVEL INDICATION


0203-B.doc

2/4

02.03

Version: 03.00 B

DOSING CONTROL

The following switching thresholds of the


indictor lamps
07.04.2):

are

STANDARD
programmed
modifiable:
FILL
LEVEL

available

=
in

(see

chapter

filling
level
values
the software and not

INDICATOR LAMP
OUTPUT
signal

Description

FULL

O-17 (red)

92 %

O-18 (white) INTERMEDIATE

69 %

O-19 (white) INTERMEDIATE

46 %

O-20 (white) INTERMEDIATE

FURNACE FULL
FILLING LEVEL
FILLING LEVEL
FILLING LEVEL

23 %

O-21
(yellow)

kg

O-04

FILLING

kg

O-04

O-04 ...
ACKNOWLEDGED

AVAILABLE VALUES = operator-specific


selectable switching levels for indicator
lamps

kg value in display - remaining available volume in


the furnace:

INTERMEDIATE
FILLING LEVEL

The operational furnace filling level is entered in


set-up mode for CELL (see chapter 07.04.3.1)
or for the HPDE (see chapter 07.04.4.1)

Additional indication for the refilling of the furnace


with a pre-set filling volume:

After this volume (kg = REFILL VOLUME) has


been dosed from the furnace, the signal O-04 is
switched from 0 to 1

After refilling (with more than kg = O-04REFILLING ACKNOWLEDGED), the signal O04 is automatically switched back from 1 to 0

***BASIC STATUS***
10.03.00
13:34:57
DOS. PIPE 65/21mm
EXT. KEY DOS-ON or F5 = DOSING

HEATING
SCAN=CELL
!

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


P r o D o s
DPC-V1.01-05 = DIE-CAST-VERSION
03.03.00
= DATE OF SETUP DATA

AVAILABLE = 890 kg MELT


SETUP

INFO

OPERAT. kg-DOS:
MODES
NEW
DOSING

The kg value of the REFILL VOLUME and for


O-04-REFILL ACKNOWLEDGED are entered in
the set-up mode for the CELL (see chapter
07.04.3.1) or the HPDE (see chapter 07.04.4.1)
respectively.

OFFLINE:
5.60kg
DOS. PIPE: 65/21mm
t6

AUTO
DOSING
SCAN=CELL ... ON

t8

t7

DCM-DIE

PROPERTIES

TS=

The CELL filling level detection and indicators are


activated when the Pro Dos DPC is switched on

In the event of disturbances of the CELL filling


level detection system, the indicator lamps are
blinking (refilling not permitted)

t9
t1

t2

DC
t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS
FURNACE FILLING LEVEL INDICATION
0203-B.doc

The HPDE filling level detection and indicators are


activated when the Pro Dos DPC is switched on
(and only if there is pressure in the furnace
chamber):

During dosing operation

If additional operating mode TOP-STOP is


selected

if additional operating mode LEVEL-SCANNING


is selected

If the refill cover is open and if the HPDE filling


level detection system is used and the furnace
chamber is not under pressure (e.g. during
disturbances), the indicator lamps are switched
to alternate blinking mode (refilling is not
permitted)

A test of the indicator lamps is carried out


automatically each time the refill cover is opened:

The indicator lamps are switched ON for approx.


5 sec. and subsequently return to their normal
mode

The switching of the red indicator lamp (FURNACE


FULL) from ON to OFF is delayed (by approx. 30
sec = standard - see chapter 07.04.2).

If the actual filling level is below the level of the


yellow indicator lamp (lowest level - O-21), this
lamp is switched to blinking (furnace should be
immediately refilled)

In the event of overfilling of the furnace, the red


indicator lamp (highest level - O-17) is switched to
blinking

IF the red indicator lamp is ON or blinking (highest


level - O-17), the cleaning manhole is automatically
locked.

The available volume in the furnace is only


indicated in the display:

in basic status (e.g. 890 kg)

and with HPDE - displayed is the last


measured value

in dosing mode (e.g. 890 kg), after AUTO


dosing process and open DCM die and when
the plunger has returned to back position:
DOSING ... ON.

Version: 03.00 B

3/4

02.03

OPERATIONAL FUNCTIONS

FURNACE FILLING LEVEL INDICATION


02.03

4/4

0203-B.doc

blank page

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC OPERATIONAL FUNCTIONS


OPERATING MANUAL

DOSING CONTROL

0204-B.doc

Version: 03.00 B

FURNACE HEATING

1/2

02.04

The Pro Dos DPC temperature regulator adjusts the


melt temperature and monitors the temperatures in the
furnace chamber.
The control of the melt temperature switches the
heating system of the WESTOMAT to FULL /
PARTIAL LOAD or OFF.
The monitoring of the furnace chamber temperature
only affects the release or locking of the heating
operation.
The temperature limit values are entered as follows:
K27. REGULATOR CONFIGUR.(TEMPERATURE)

In
set-up
mode
of
the
REGULATOR
CONFIGURATION (see chapter 07.03.1):

= Xshmin Toggling FULL/PARTIAL:

Switching from FULL LOAD to PARTIAL LOAD


heating while melt temperature is increased,
and value (X)-ACTUAL is below the value (W)NOMINAL, e.g. 5 lower

= Xshmin Toggling FULL/PARTIAL:

Switching from PARTIAL LOAD to FULL LOAD


heating while melt temperature is lowered, and
value (X)-ACTUAL is below the value (W)NOMINAL, e.g. 3 lower

850

= AL3 Furnace chamber

AL3 furnace chamber Locking of the heating


operation, if the furnace chamber temperature
exceeds a certain value, e.g. 850

750

= AL-08-HEATING-overtemperature

AL-08 OVERTEMPERTURE Signalling of


DISTURBANCE: HEATING ALARM, if the value
(X)-ACTUAL of the melt exceeds the entered
value, e.g. 750 Risk of overheating

AL-08 UNDERTEMPERTURE Signalling of


DISTURBANCE: HEATING ALARM, if the value
(X)-ACTUAL of the melt is below the entered
value, e.g. 640 Risk of hardening of melt

640

= AL-08-HEATING-overtemperature

MELT TEMPERATURE

By entry of operating temperature values for the


melt - / T (see chapter 06.06):

Entry of temperature value-(W)-NOMINAL:

At an increase in melt temperature


exceeding the limit value, the heating system
is switched from PARTIAL LOAD to OFF

At decreasing melt temperature and a


temperature below the limit value, the
heating system is switched from OFF to
PARTIAL LOAD

695C = NOMINAL VALUE MELT

-10C = UNDERTEMPERATURE MELT

+15C = OVERTEMPERATURE MELT

Entry of a qualitatively reliable min. limit value


for the deviation of the value (X)-ACTUAL of the
melt temperature and locking of dosing if this
limit is exceeded

Entry of a qualitatively reliable max. limit value


for the deviation of the value (X)-ACTUAL of the
melt temperature and locking of dosing if this
limit is exceeded.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FURNACE HEATING
02.04

2/2

0204-B.doc

Version: 03.00 B

The values (W)-NOMINAL and (X)-ACTUAL for the


melt temperature are displayed at the front panel see
chapter 01.01.2:

If the EMERGENCY HEATING mode is selected,


value X (ACTUAL melt temperature) is blinking and
the displayed value does not correspond to the
actual value.

In the event of a DISTURBANCE: HEATING


ALARM switches both values ( X and W ) to blinking

IN the event of a thermocouple failure (output O08 = 1 and DISTURBANCE: HEATING ALARM), the
displayed temperature value does not correspond
with the actual value.

DOSING CONTROL

694
W

695

By means of the help function key i / T, all


temperatures as well as the operating hour counters of
the heating stages can be called up on the display.
TEMPERATURE

MELT

FURNACE CHAMBER

ACTUAL
= 694C
= 723C
NOMINAL
= 695C
OVERTEMPERATURE =
15C
= 850C
UNDERTEMPERATURE =
10C
OPERATING HOURS COUNTER-HEATING
FULL LOAD OPERATION
=
126:34/h
PARTIAL LOAD OPERATION
= 10942:43/h

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

0205-B.doc

Version: 03.00 A

1 / 12

OPERATING MODES

02.05

For DOSING and HEATING operation, the dosing


furnace can be operated in the following OPERATING
MODES:

Dosing with or without TOP-STOP

Dosing with or without LEVEL-SCANNING

Dosing with or without SYNCHRONIZATION

Synchronized with DCM status DIE CLOSED

Synchronized with DCM status DIE READY


FOR INJECTION

WEEKEND REDUCTION of melt temperature

EMERGENCY HEATING

SELECTION of OPERATING MODES


***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

The selection of a specific operating mode is carried


out in the BASIC STATUS of the Pro Dos DPC.

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

Press multi-function key

F3

= OPERATING

MODES

F1

F2

F3

F4

F5

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The SELECTION of a specific OPERATING MODE
may be locked under certain circumstances. The
code lock prevents unauthorised manipulation at
the Pro Dos DPC and is recorded in the log (K
12).

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
0205-B.doc

2 / 12

02.05

Version: 03.00 A

If the access to the OPERATING MODE


SELECTION is locked by code, proceed as follows:

F3

press multi-function key

The display form with instructions for entry of


the code number appears

Enter code number and press

If the access to the OPERATING MODE


SELECTION is not locked by code, proceed as
follows:

10.03.00
SETUP MODE:
CELL-FILLING-INDIC. 13:34:57 SCAN=CELL
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL

The SELECTION for OPERATING MODES is


now available

DOSING CONTROL

F3

press multi-function key

******

= ENTRY CODE-N and ENTER

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDIC. 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back

The display form with instructions appears

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL

Press

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL

The SELECTION for OPERATING MODES is


now available

CONTINUE PROCEDURE WITH ENTER

Change OPERATING MODES as required

With

or

, place cursor in line

F1

MEMO

and

(MEMORY=YES) = save

to DEACTIVATE mode, press:

0
F1

MEMO

HEATING
SCAN=CELL

SETUP OPERATING MODES

To ACTIVATE the selected mode, press

10.03.00
13:34:57

, INPUT, ENTER and MEMO / ESC=back

of desired operating mode

***BASIC STATUS***
DOS. PIPE 65/21mm

and

(MEMORY=YES) = save

ATTENTION

The operating mode LEVEL-SCANNING is only


available in conjunction with TOP-STOP = 1.

Only one type of SYNCHRONIZATION can be


selected at any one time. To select a new type
of sychronization, set the previously selected
type to 0.

1 = with TOP-STOP

YES=1 NO=0

1 = with LEVEL-SCANNING

YES=1 NO=0

1 = with SYNCHRONIZING to DCM-signal


DIE CLOSED 1
YES=1 N0=0
0 = with SYNCHRONIZING to DCM-signal
DIE READY TO INJECT 1 YES=1 N0=0
0 = with weekend temp. reduction
of melt
YES=1 NO=0
0 = EMERGENCY HEATING
YES=1 NO=0
in case of the th-couple melt is
damaged:
0312 " - EMERG.-operation via
thermocouple of furnace chamber
INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

OPERATING MODES
0205-B.doc

Version: 03.00 A

3 / 12

02.05

OPERATING MODE TOP-STOP


In dosing mode TOP-STOP, the cast cycle time for
individual casts (t8 = DCM INJECTION STOP TIME
FOR DOSING) remains constant irrespective of the
furnace filling level.
In operating mode with TOP-STOP, the melt is kept in
the dosing pipe:

by means of overpressure in the furnace chamber

independently of the furnace filling level

at a given distance from the dosing pipe outlet edge


(distance to dosing contact).

This distance is defined by the TOP-STOP


pressure in the furnace chamber (see LOG K06 TOP-STOP PRESSURE below P-DC).
FEATURES

This option can be selected for both AUTO and


MANUAL dosing.

It is only available after the TOP-STOP option has


been selected (1 = YES)

The dosing process time t2 from PRESSURE


START to DC is constant between 1 and 1.5 sec,
irrespective of the furnace filling level

The PRESSURE START for dosing is initiated from


the TOP-STOP pressure

after dosing END (t5 = END), the TOP-STOPpressure is built up again.

If the refill cover is opened and LEVEL-SCANNING


is not selected:
The furnace chamber is deaerated (TOP-STOP
discontinued)
the dosing process is initiated from the
pressure-free furnace chamber.
After closing of the refill cover and successful
dosing process, the TOP-STOP pressure is built
up again

In the event of disturbances, the furnace chamber


is deaerated and TOP-STOP is discontinued.
ATTENTION
Prior to the activation of TOP-STOP, ensure that
the CD (electrode or PneuCo) works properly.
During the activation of TOP-STOP, the metal feed
channel must be observed. In the event of metal
feed, immediately press EMERGENCY STOP.
By releasing the key DOS-ON during TOP-STOP
activation, the furnace chamber is deaerated and
the display changes to F5-STATUS, showing the
following instruction:
- POSITION ERROR: TOP-STOP
If LEVEL-SCANNING is not selected, the TOPSTOP must be activated while the refill cover is
closed.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
4 / 12

02.05

0205-B.doc

Version: 03.00 A

DOSING CONTROL

ACTIVATING TOP-STOP
Press (and hold) DOS-ON key (I-08 = from 0 to 1) to
activate TOP-STOP.

The furnace chamber pressure increases and the


melt in the dosing pipe rises. The indicator lamp
READY FOR OPERATION (O-22) is blinking.

The rising melt in the dosing pipe establishes DC.


No metal feed is carried out and the furnace
pressure is reduced.

After completion of the pressure reduction, the


furnace chamber pressure is adjusted to TOPSTOP pressure.

P = mbar
DC

P DC
P TS

t = sec
O - 22

After the TOP-STOP pressure has been reached,


the activation is completed. The indicator lamp for
READY FOR OPERATION ceases to blink. Release
key DOS-ON (I-08 = 1).

I - 08

VISUALISATION (DISPLAY)

TOP-STOP is activated

OFFLINE:
4.65kg
MANUAL
DOSING
SCAN=CELL ... END
DOS. PIPE 65/21mm
TOP-STOP = activate
TOP-STOP = is being prepared

- this operational mode is selected


- hold external key DOS-ON
until TOP-STOP ready for operation!
MODIFY
INFO
DATA
DOSING
TOP-STOP activation has been interrupted -display
switches to F5-STATUS
OFFLINE:
4.65kg
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
position error: TOP-STOP / ESC=back
TOP-STOP = not operational
- this operational mode is selected
- hold external key DOS-ON
until TOP-STOP ready for operation!

INFO

... TOP-STOP is activated

TS=

MODIFY
DATA

kg-DOS:

NEW

DOSING

ATTENTION

TS=

... TOP-STOP is activated and

furnace is dosing

TOP-STOP is activated after completion of


dosing process.

The refill cover is open


SCANNING is activated

and

LEVEL-

The refill cover is open


SCANNING is not selected

and

LEVEL-

OFFLINE:
4.65kg
DOS. PIPE 65/21mm
t6

AUTO
DOSING
SCAN=CELL ... ON

t8

t7

DCM-DIE
TS=

t9
t1

t2

DC
t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA
DOSING

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

OPERATING MODES
0205-B.doc

Version: 03.00 A

5 / 12

02.05

OPERATING MODE LEVEL-SCANNING


In WESTOMAT units with HPDE, LEVEL-SCANNING
is used for the indication of the furnace filling level.
The LEVEL-SCANNING consists of:

The actual SCANNING process:

Increase of furnace chamber pressure, rise of


melt in dosing pipe to CD (no metal feed)

Measuring of the furnace chamber pressure at


the moment of DC (P -CD)

Reduction of the furnace chamber pressure and


adjustment to the level of the LEVELSCANNING pressure (resulting from the TOPSTOP pressure)

Updating of the filling level indication on the display


(according to current P-DC)

Cycle time of the next SCANNING process (see


LOG K19 - CYCLE FOR LEVEL-SCANNING

Holding of furnace chamber pressure at the level of


the LEVEL-SCANNING pressure during cycle time;
holding of melt in dosing pipe at a given distance
from the outlet edge (to DC).

In WESTOMAT units with load cell (CELL), the


updating of the filling level display is based only on the
CELL, and LEVEL-SCANNING can only be activated
as a process function.
FEATURES

This option can be selected for both AUTO and


MANUAL dosing.

It only operates after the TOP-STOP and LEVELSCANNING options have been selected (1 = YES)

It can be activated during dosing operation by


opening the refill cover

SCANNING processes are only carried out during


dosing breaks

The updating of the filling level display is carried


out in cycles together with the furnace chamber
pressure values and at the moment of DC (P -DC)

The PRESSURE START for dosing is initiated from


the TOP-STOP pressure

after DOSING END (t5 = END), the LEVELSCANNING process is restarted

In the event of disturbances, the furnace chamber


is
deaerated
and
LEVEL-SCANNING
is
discontinued.

During interruptions in LEVEL-SCANNING, the fill


level indictors are switched to warning status.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
02.05

6 / 12

0205-B.doc

Version: 03.00 A

DOSING CONTROL

ACTIVATING LEVEL-SCANNING
LEVEL-SCANNING is activated by opening the refill
cover (I-14 = from 0 to 1) during dosing operations:

The furnace chamber pressure is increased and the


melt in the dosing pipe rises:

an AUTO DOSING START initiated during this


stage is only completed after the LEVELSCANNING pressure (P-LS ) is reached.

The melt rising in the dosing pipe establishes DC


(no metal flow) and:

The furnace chamber pressure is measured (P DC)

The filling level display is updated

The furnace chamber pressure is reduced

After completion of the pressure reduction, the


furnace chamber pressure is adjusted to LEVELSCANNING pressure (P-LS )

When the LEVEL-SCANNING pressure (P-LS ) is


reached, the SCANNING process is completed:

The cycle time (t -LS ) to the next SCANNING


process is started

All previously activated AUTO DOSING STARTs


are realized.

After closing of the refill cover and lapse of the cycle


time (t -LS ), the unit automatically resumes operation
and completes
one SCANNING process - continue with

activating
TOP-STOP
pressure P-TS is reached.

P DC-1

P DC-2

P TS
P LS-1
P LS-2
t LS
t = sec

P = mbar
DC

(until

TOP-STOP

ATTENTION
The SCANNING process is initiated by opening the
refill cover during dosing operation and starts after
DOSING END.
The opening of the refill cover (activation of LEVELSCANNING) is only required for refilling or the
cleaning of the filling funnel.
If no refilling (or cleaning) is to be carried out, the
refill cover can be kept closed.
If the LEVEL-SCANNING is discontinued (filling
level indicator lamps in warning status - blinking in
sequence and only one lamp ON), refilling is not
permitted.

I - 14
I - 08

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

OPERATING MODES
0205-B.doc

Version: 03.00 A

7 / 12

02.05

OPERATING MODE SYNCHRONIZATION


The synchronization of the WESTOMAT dosing
process and the DCM die closing ensures the shortest
cycle time per casting (t8 = DCM INJECTION STOP
TIME TO DOSING).
The operation of the dosing process is coordinated
with the DCM die in such a manner that approx. 60%
to 70% of the dosing cycle time from pressure rise to
DC (t2) is shared with the closing movement time of
the DCM die.
SELECTION
Synchronization can be selected in two ways:

standard synchronization based on the DCM die


closing status DIE CLOSED (the movable die plate
has closed over the shot sleeve)

special synchronisation (e.g. for three-plate dies)


based on the DCM die closing status DIE READY
FOR INJECTION (the closing part of the DCM die is
locked):

In such cases, it might be necessary to increase


the time parameter from 0.5 to 1.0 sec in LOG
K11.

By entering 0 for both synchronization options, the


unit remains in asynchronous mode.

FEATURES
The process synchronization is only carried out in
AUTO-DOS mode and:

and in conjunction with:


TOP-STOP (activated)
SYNCHRON. (with DIE CLOSED) or
SYNCHRON.
(with
DIE
READY
INJECTION)

FOR

after n AUTO-DOS processes in sequence, (n number of cycles according to LOG K11)

if no discontinuation is activated (i.e. if DCM signals


I-25, I-26 and / or I-27 = 0)

after the second AUTO-DOS process in sequence,


after acknowledging a discontinuation (i.e. if I-25, I26 and / or I-27 = from 1 to 0)

after it has been established that no metal is fed


into the already closed shot sleeve.
During refilling of the furnace and in special cycles of
the DCM, synchronization is discontinued.

at start of production (reduced plunger force, DCM


signals I-25 or I-26 = 1)

at cyclic testing of the hydraulic die tension test


device (DCM signal I-25 = 1)

at automatic readjustment of the DCM closing


performance (DCM signal I-25 = 1)

at dosing volume reduction or increase (DCM


signal I-26 and / or I-27 = 1)

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
02.05

8 / 12

0205-B.doc

Version: 03.00 A

DOSING CONTROL

After completion of DOSING (t5-END), RELEASE


FOR PRESS (t8-END) is signalled.

By means of synchronization, the AUTO dosing


process is coordinated with the closing movement of
the DCM DIE in the following manner:

With the closing of the DCM die (I-19), the


synchronization time t1 is started
The automatic optimisation feature of the
Pro Dos DPC computes the synchronization
time t1, taking into consideration the LOG time
for DCM RELEASE FOR INJECTION to DC
(Standard time = 0.5 sec - see log K11)

at t1 -END, the pressure increase to DC is started


from TOP-STOP in the furnace chamber (t1START).

In the mean time, DCM DIE CLOSED (I-20 and I21) is signalled.
The melt in the dosing pipe reaches DC (t2-End)
and metal feed is started (t3-START)
During metal feed (t3 and t4), DCM DIE READY
FOR INJECTION (I-22 and I-23) is signalled

FLOW DIAGRAM: AUTO-SYNCHRON.-DOS (synchronous with DIE CLOSED)


I-19 = 1

I-20 (21) = 1

I-22 (23) = 1

I-24 = 1

t7

t6

t8
1

t9 (DC)

TS=

t2

t3

t4

t5

ALU - DOS

FLOW DIAGRAM:
INJECTION)
I-19 = 1

AUTO-SYNCHRON.-DOS

I-20 (21) = 1

t6

(synchronous

with

I-22 (23) = 1

DIE

READY

FOR

I-24 = 1

t7

t8
1

t9 (DC)

TS=

t1

t2

t3

t4

t5

ALU - DOS

DCM SIGNALS

WESTOMAT CYCLE TIMES

I-19
I-20
I-21
I-22
I-23
I-24

t1
t2
t3
t4
t5
t6

=
=
=
=
=
=

DIE CLOSES
DIE CLOSED
DIE CLOSED
DIE READY FOR INJECTION
DIE READY FOR INJECTION
PLUNGER IN BACK
POSITION

ALU-DOS = METAL FEED

=
=
=
=
=
=

Synchronization time
Pressure rise to DC
Dosing pressure increase time
Feed time
Lag time
Closing time until
DIE CLOSED

t7 =

Closing from
DIE CLOSED to READY
FOR INJECTION
t8 = INJECTION STOP-TIME of
DCM to DOSING
t9 = Time from DCM READY
FOR INJECTION
to DC *(dosing contact)

WESTOMAT ProDos DPC


OPERATING MANUAL

OPERATIONAL FUNCTIONS

OPERATING MODES
0205-B.doc

DOSING CONTROL

Version: 03.00 A

9 / 12

02.05

If no synchronization option is selected, an AUTOASONCHRON. dosing cycle is stared, after the DCM
has been fully closed and READY FOR INJECTION
has been signalled.

FLOW DIAGRAM: AUTO-ASYNCHRON.-DOS (not synchronized)


I-19 = 1

I-20 (21) = 1

t6

I-22 (23) = 1

t8
1

TS=

I-24 = 1

t7
2

t9 (DC)

t2

t3

t4

t5

ALU - DOS

The above flow diagram shows:

The optimum cycle time per cast (t8 = DCM


INJECTION STOP-TIME to DOSING) is achieved
with synchronization based on DCM DIE CLOSED.

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
10 / 12

02.05

0205-B.doc

Version: 03.00 A

DOSING CONTROL

OPERATING MODE WEEKEND REDUCTION OF


MELT TEMPERATURE
This operating mode reduces the energy consumption
for temperature holding and helps thus save costs.
Costs can be reduced if:

the operating temperature of the melt is usually


higher than 750C

the standstill over the weekend is longer than 24


hours.

FEATURES

This operating mode is only recommended if the


properties and quality of the aluminium alloy are
not impaired by the temperature reduction.

650C = lowest holding temperature in reduction


mode

During temperature reduction, dosing operation is


locked

When entering the time for switching back to


normal operation, please take the following heating
rates for the melt into account:
approx. 15C / hour - for full furnace
approx. 20C / hour - for half-filled furnace

As soon as this operating mode is deactivated, the


unit returns to normal operating mode.
ACTIVATING
REDUCTION

WEEKEND

TEMPERATURE

10.03.00
SETUP MODE:
TEMPERATURE REDUCT. 13:34:54
, MODIFY +,- AND ENTER / ESC=back
K25. TEMPERATURE REDUCTION (MELT)

The
operating
parameters
for
the
weekend
temperature reduction are entered and saved in the
setup mode for REGULATOR HEATING / TREDUCTION (see chapter 07.03.2):

Day and time of activation

Weekday and time for switching back to normal


operation

value by which the holding temperature is to be


reduced

SATURDAY
23:30

= start of reduction
= time

MONDAY
02:30

= end of reduction
= time

-100

After activating
automatically

this

operating

mode,

switches on temperature reduction

and switches back to normal operation

according to the entered data

the

unit

INFO

C = Temperature reduction by

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATIONAL FUNCTIONS

OPERATING MODES
0205-B.doc

Version: 03.00 A

11 / 12

02.05

OPERATING MODE EMERGENCY HEATING


In the event of a failure of the melt temperature
monitoring system (e.g. at melt thermocouple), the
holding operation is disrupted and dosing operation is
locked. Immediately repair fault.
For the time until the repair is completed, the
WESTOMAT can temporarily be operated by means
of the EMERGENCY HEATING.
In this operating mode, the temperature regulation of
the melt is carried out by means of temperature
measuring in the furnace chamber.
FEATURES

694
W

695

10.03.00
SETUP MODE:
13:34
REGULATOR CONFIGUR.
, INPUT, ENTER and MEMO / ESC=back
K27. REGULATOR CONFIGUR.(TEMPERATURE)
EMERG.-operation via thermocouple

When the EMERGENCY HEATING is activated, the


display of the (X)-ACTUAL value of the melt
temperature is blinking

The nominal value for the holding temperature


remains unaltered

In this operating mode, the monitoring of the melt


temperature is discontinued.

The actual temperature of the melt can


maintained with an accuracy of approx. 10

be

ACTIVATING EMERGENCY HEATING


The operating parameters of the power switching
(switching parameters) are entered and saved in the
setup modes REGULATOR HEATING / REGULATOR
CONFIGURATION (see chapter 07.03.1):

20

= from FULL to PARTIAL LOAD

switching from FULL LOAD to PARTIAL LOAD at


rising temperature

50

= at part. load OFF

switching from PARTIAL LOAD to OFF at rising


temperature

35

= OFF to part. load

switching from OFF to


decreasing temperature

= part. to full load

switching from PARTIAL LOAD to FULL LOAD at


decreasing temperature

INFO

PARTIAL

LOAD

After repair of the temperature monitoring system:

deactivate this operating mode.

The system returns to normal holding mode.

at

OPERATIONAL FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING MODES
02.05

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0205-B.doc

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Version: 03.00 A

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

0300-A1.DOC

Version: 12.99 A

1-

14

STRUCTURE OF OPERATOR INTERFACE

03.00

OPERATING and DISPLAY ELEMENTS


The WESTOMAT Pro Dos DPC is connected to
several external operating elements located at the
switch cabinet door or the control desk:

Illuminated key DOS-ON


- to activate the dosing operation
- the lamp indicates that the unit is switched ON

Key DOS-OFF
- to deactivate dosing operation

Illuminated key DISTURB ACKNOWL


- to acknowledge disturbances
- the lamp (blinking) indicates an error
message

Lamp DOS-READY
- if switched ON - indicates ready for operation
WESTOMAT and DCM ready for dosing
- if lamp BLINKING - indicates
activation of operating mode TOP-STOP

Lamp DOSING
- if switched ON - indicates that dosing operation
is running

Key EMERGENCY STOP


- EMERGENCY STOP of dosing operation

Key DOOR OPEN


- to unlock solenoid lock of the cleaning
manhole of the WESTOMAT

Key MANUAL DOS


- optional key
- to start dosing process in MANUAL
DOSING

Key HORN ACKNOWL


- optional key
- to switch off horn

The following operating and visualisation elements are


located at the front panel of the Pro Dos DPC:

DISPLAY
see chapter 01.01.1

MULTI-FUNCTION KEYS (F1 to F5)


see chapter 01.01.3

HELP KEYS
see chapter 01.01.3

NUMERICAL KEYBOARD
see chapter 01.01.3

ARROW KEYS
see chapter 01.01.3

TEMPERATURE INDICATOR
- display only with activated internal regulator
- see chapter 01.01.2.

OPERATOR INTERFACE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

STRUCTURE OF THE OPERATOR INTERFACE


2 - 14

03.00

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Version: 12.99 A

DOSING CONTROL

Depending on the operating mode of the Pro Dos


DPC, the current functions of the MULTI-FUNCTION
KEYS (F1 to F5) are shown in the respective display
fields.

= external illuminated key DOS-ON

The diagram GENERAL OVERVIEW shows all basic


functions of these keys.

= external key DOS-OFF

F1

= MULTI-FUNCTION KEY

Operator interface: GENERAL OVERVIEW


F5

DOSING

without code
locking

Query of READY FOR OPERATION of WESTOMAT, position of DCM-DIE and


operating instructions for DOS-ON

F1

F4

F2

OPERAT.
MODES

SETUP

ESC = back

Entry form for new kg dosing volume including kg-REDUCTION, kg-INCREASE,


FURNACE CHAMBER CORRECTION and t5 = LAG TIME

kg-DOS:
NEW

F1
F3

INFO

F5

with coding lock

REGULATOR
HEATING

INFO

ESC = back

Operation WITH = 1 or WITHOUT = 0 for: TOP-STOP / LEVEL-SCANNING /


SYNCHRONIZATION / melt temperature REDUCTION / EMERGENCY HEATING
F1

INFO

F5

REGULATOR
CONFIG.

ESC = back

with coding lock

Enter date of regulator configuration and


save
F1

F4

INFO

INFO

F4

kg-DIAGRAM

INFO
with coding lock

LDH-SETUP

F2

FILL.
LEVEL

INFO

DOS-ON

Query of READY FOR OPERATION of WESTOMAT,


activation of TOP-STOP and display of DCM-DIE position
Activation of TOP-STOP
Display of DCM-DIE position

INFO

ESC = back

DOS-OFF

ESC = back

ESC = back

Enter data of initial LOG and save

LOG
DATA

INFO

ESC = back

Enter processes and data of the filling level monitoring by


means of CELL or HPDE system and save

F1

INFO

INFO

Set Hour / Date / Language

F1
F1

INFO

Enter processes and data for REFERENCE and OPERATING


kg-DIAGRAM of the dosing volumes and save

F1
F1

ESC = back

ESC = back

F1
F3

Activate / deactivate warm-up


programme of the furnace (cold start)

FIRST
WARM-UP

F1
F1

ESC = back

Enter data for weekend reduction of melt


temperature and save

TEMP.
REDUCTION

F1
F3

ESC = back

MANUAL or AUTO-DOSING MODE in


conjunction with DCM signal interface

ESC = back to BASIC STATUS

ESC = back to initial status

F5-STATUS and display of position errors


(e.g. position error: TOP-STOP)

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

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03.00

FUNCTION KEY: F5 = DOSING


Press function key F5 = DOSING in BASIC STATUS
to activate query-MODE (F5-STATUS) for:

READY FOR OPERATION of WESTOMAT


Non-conforming signal status are indicated as
ERRORS

DCM-DIE position
Non-conforming signal status are indicated as
POSITION ERRORS

A number of other keys are available in F5-STATUS


of the Pro Dos DPC - see diagram.

FUNCTION KEY: F4 = kg-DOS: NEW


Press function key F4 in BASIC STATUS to access
entry form for the data of a new dosing volume:

Required dosing volume in kg


Required kg-REDUCTION
Required kg-INCREASE
% value of FURNACE CHAMBER CORRECTION
sec value of t5 = LAG TIME.

FUNCTION KEY: F3 = MODIFY DATA


Press function key in DOSING STATUS to modify the
data of an entered dosing volume

Operator interface in F5-ST AT US


F5

DOSING

without code
locking

Query of READY FOR OPERATION of WESTOMAT, position of DCM-DIE and


operating instructions for DOS-ON

F1

F4

kg-DOS:
NEW

F1

F3

MODIFY
DATA

F1

F1

DOS-ON

F1

INFO

ESC = back
INFO
without code
locking
ESC = back
INFO
without code
locking
ESC = back
INFO

ESC = back

DOS. PIPE
selection

Entry and
ENTER

DOS-OFF

MEMO and
F1 or F3 / F5

ESC = back
MEMO and
F1 or F3 / F5

ESC = back

ESC = back

Query of READY FOR OPERATION of WESTOMAT,.


activation of TOP-STOP and display of DCM-DIE position
Activation of TOP-STOP
Display of DCM-DIE position
INFO

Data entry and


ENTER

MANUAL or AUTO-DOSING MODE in


conjunction with DCM signal interface

ESC = back to BASIC STATUS

ESC = back to initial status

F5-STATUS and display of position errors


(e.g. position error: TOP-STOP)

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


4 - 14

03.00

0300-A1.DOC

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

FUNCTION KEY: F3 = OPERATING MODES


ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

Press function key F3 = OPERATING MODES in


BASIC STATUS to access entry form for the selection
of WESTOMAT operating modes:

with / without TOP-STOP

with / without LEVEL-SCANNING

with / without SYNCHRONIZATION with the DCMDIE closing movement:

SYNCHRONIZATION with DCM signal: DIE


CLOSED

SYNCHRONIZATION with DCM signal: DIE


READY FOR INJECTION

with / without WEEKEND MELT TEMPERATURE


REDUCTION

with / without EMERGENCY HEATING (without


melt thermocouple).

Operator interface for: OPERAT ING M ODES

F3

with coding lock

TOP-STOP (hold furnace chamber


pressure prior to dosing)

LEVEL-SCANNING (during refill)

SYNCHRONIZATION until die closed

SYNCHRONIZATION until die ready for


injection

WEEKEND MELT TEMPERATURE


REDUCTION

EMERGENCY HEATING (without


thermocouple melt)

ESC = back

OPERATING
MODES

F1

ESC = back
INFO

1 = with / 0 = without:
and ENTER

MEMO and
F1 or F3 / F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

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03.00

FUNCTION KEY: F2 = SETUP (GENERAL)


Press function key F2 = SETUP in BASIC STATUS to
access SETUP MODE:

LDH SETUP (Language / Date / Hour)

LOG DATA

REGULATOR HEATING

FILLING LEVEL INDICATION

kg-DIAGRAM

For the INITIAL SETUP of the Pro Dos DPC (or after
installation of an incompatible software version) the
above listed sequence of setup procedures is
automatically applied and must be followed.

SETUP MODE = LDH SETUP


ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

In this setup mode, enter the current time and date


and the language of the programme interface.

Operator interface for: LDH SETUP

F3

LDH-SETUP

with coding lock

F3

HOUR

Entry and ENTER

F4

DATE

F5

LANGUAGE

ESC = back

ESC = back

ESC = back

Entry and ENTER

ESC = back

Entry and ENTER

ESC = back

ESC = back

ESC = back

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


6 - 14

03.00

0300-A1.DOC

WESTOMAT P ro Dos DPC


OPERATING MANUAL

Version: 12.99 A

SETUP MODE: LOG DATA


ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

In this setup mode, the specific data of the


WESTOMAT unit - see log K01 to K12 (including the
freely selectable code number) - are entered and
saved. If zero is entered as code number, the coding
lock is deactivated for all setup procedures.
From K13 onwards, the parameters from other setup
procedures are only displayed as read-only data and
cannot be modified in the LOG DATA setup.

Operator interface for: LOG DAT A

F1

LOG
DATA

with coding lock

Entry of data for K01 to K12 and ENTER

F1

ESC = back

ESC = back
INFO

ESC = BACK

MEMO and
F1 or F3 / F5

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

Version: 12.99 A

7 - 14

03.00

SETUP MODE: FILLING LEVEL


INDICATION (CELL)
ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

Depending on the actual equipment of the


WESTOMAT (for the monitoring of the filling level in
the furnace), enter:

CELL = 1 / if the filling level is monitored by


means of a load cell, or

HPDE = 0 / if the filling level is monitored by


means of a hydraulic-pneumatic pressure
detection system

in the LOG of the ProDos DPC and save.


The following processes are implemented by means
of the FILLING LEVEL INDICATION setup mode:

CELL-SYSTEM and subsequent procedures:

DATA INPUT:
- Entry of basic values

CELL-mA SIGNAL:
- Signal range for furnace operating level
(operating level FULL to EMPTY)

P/t-MIN-MEASURING:
- Pressure and time detection at dosing
contact (DC)

If two dosing pipes are entered in the LOG, these


settings must also be completed for the second
pipe.

SIGNAL COMPENSATION:
- subsequent compensation (correction) of the
signal range for the furnace filling level.

DISPLAY MODE:

Selection of preset display options for the


filling level indicator lamps.

SWITCHING THRESHOLDS:

STANDARD VALUES:
- The distances between the indicated filling
levels are pre-set in the software

SELECTABLE VALUES:
- The distances between the indicated filling
levels can be selected by the operator.

OPERATOR INTERFACE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

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Version: 12.99 A

DOSING CONTROL

SETUP MODE: FILLING LEVEL


INDICATION (CELL)
(continued)

Operator interface for: FILLING LEVEL INDICATION CELL

F2

FILLING
LEVEL

with
coding lock

ESC = back

F1

INFO

F2

CELL
SYSTEM

ESC = back

F1

INFO

F2

D AT A
ENTRY

Entry and ENTER

F1

F3

CELL
S I G N AL

P/t-MINM E AS .

S I G N AL
COMP.

F5

DISPLAY
MODE

SWITCH.
THRESH.

INFO

ESC = back

INFO

INFO

ESC = back

Setup and
ENTER

MEMO and
F1 or F3 / F5

MEMO and
F1 or F3 / F5

ESC = back

Set up limit signal CELL 0 and furnace MEMO and


F1 or F3 / F5
FULL and ENTER
ESC = back
F1

F4

ESC = back

Selection of
dosing pipe and
ENTER
ESC = back
F1

F5

MEMO and
F1 or F3 / F5

Set all limit signals and confirm with


ENTER
ESC = back
F1

F4

ESC = back

INFO

Select display
mode and ENTER

MEMO and
F1 or F3 / F5

F1

INFO

ESC = back

TF
1

INFO

ESC = back

F5

SELECT
VALUES

F1

INFO

F4

VALUES

ESC = back

ESC = back

Value = 1 and
ENTER

MEMO and
F1 or F3 / F5

F4

Entry and
ENTER

MEMO and
F1 or F3 / F5

F5

RESET

MEMO and
F1 or F3 / F5

F1

F1

ESC = back

INFO

INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

Version: 12.99 A

9 - 14

03.00

SETUP MODE = FILLING LEVEL


INDICATION (HPDE)
ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

Depending on the actual equipment of the


WESTOMAT (for the monitoring of the filling level in
the furnace), enter:

CELL = 1 / if the filling level is monitored by


means of a load cell, or

HPDE = 0 / if the filling level is monitored by


means of a hydraulic-pneumatic pressure
detection system.

in the LOG of the ProDos DPC and save.


The setup mode for FILLING LEVEL INDICATION HPDE should also be completed if the WESTOMAT is
equipped with a CELL system. In the event of failure
of the CELL system, the furnace filling indication can
be switched over to the HPDE system (in setup LOG
DATA).
The following processes are implemented in this
setup mode:

HPDE-SYSTEM and subsequent procedures:

DATA INPUT:
- Entry of basic values

P/t-MIN-MEASURING:
- Pressure and time detection at dosing
contact (DC)

ATTENTION
If two dosing pipes are entered in the LOG, these
settings must also be completed for the second
pipe.

DISPLAY MODE (see also CELL):

Selection of preset display options for the


filling level indicator lamps.

SWITCHING THRESHOLDS (see also CELL):

STANDARD VALUES:
- The distances between the indicated filling
levels are preset in the software

SELECTABLE VALUES:
- The distances between the indicated filling
levels can be selected by the operator
.

OPERATOR INTERFACE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

10 - 14

03.00

Version: 12.99 A

DOSING CONTROL

SETUP MODE = FILLING LEVEL


INDICATION (HPDE)
(continued)

Operator interface for: FILLING LEVEL INDICATION HPDE

F2

FILLING
LEVEL

with
coding lock

ESC = back

F1

INFO

F2

HPDESYSTEM

ESC = back

F1

INFO

F4

D AT A
ENTRY

Entry and
ENTER
ESC = back
F1

F5

P/t-MINM E AS .

F1

F5

DISPLAY
MODE

SWITCH.
THRESH.

INFO

Selection of
dosing pipe and
ENTER

F4

ESC = back
MEMO and
F1 or F3 / F5

ESC = back

Setup and
ENTER

MEMO and
F1 or F3 / F5

ESC = back
INFO

Select display
mode and ENTER

MEMO and
F1 or F3 / F5

F1

INFO

ESC = back

F1

INFO

ESC = back

F5

SELECT
VALUES

F1

INFO

F4

VALUES

ESC = back

ESC = back

Value = 1 and
ENTER
F4

Entry and
ENTER

MEMO and
F1 or F3 / F5
MEMO and
F1 or F3 / F5
F1

F5

RESET

MEMO and
F1 or F3 / F5
F1

ESC = back

INFO

INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

Version: 12.99 A

11 - 14

03.00

SETUP MODE: kg - DIAGRAM


ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

The access to the setup mode can be locked by a


code.
According to the actual WESTOMAT equipment for
dosing, one or two dosing pipe sizes must be entered
in the LOG of the Pro Dos DPC.
ATTENTION:

If there are two dosing pipes in the


LOG, this setup procedure must
also be completed for the second
pipe

In this setup mode, the dosing volume range suitable


for the specific dosing pipe of the WESTOMAT is
entered and saved. The dosing volume range is
entered in two steps:

REFERENCE kg-DIAGRAM:

In this menu-supported processes, the reference


dosing volumes (RDVs) are
- dosed
- The parameters of the dosing process are
determined by the Pro Dos DPC
- The dosing result is evaluated independently
(weighing of castings)
- The kg-results of the required RDVs are entered
and saved.

OPERATION kg-DIAGRAM:

In this menu-supported process, the data of the


REFERENCE kg-DIAGRAM are:
- transferred without modifications and saved, or
- transferred and modified by means of additional
entries of a smaller and/or larger dosing volume
than that established in the REFERENCE kgDIAGRAM. The dosing volume range is thus
extended
- This extension can also be completed at a later
stage.

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

12 - 14

03.00

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE = kg - DIAGRAM


(continued)

Operator interface for: kg - DIAGRAM

F4

kg
DIAGRAM

with code
locking

F1
F5

ESC = back
INFO

ESC = back

REFERENCE DOS. PIPE


selection
DATA

Delete or modify / RDV selection


ENTER

continue with key


F5 = DOSING

Press key F5 = DOSING: Query of READY FOR OPERATION of


WESTOMAT, position of DCM-DIE and operating instructions for DOS-ON
In MANUAL DOSING mode with TOP-STOP, implementation of the
required Reference Dosing Volumes (RDV) and calculation of kg-DOS
results (weighing)
Enter calculated kg-DOS volumes for MEMO and
ESC = back
F1 or F3 / F5
all implemented RDVs and ENTER

F4

OPERAT.
DATA

ESC = back

DOS.
PIPE
selection
and
ENTER

F5

F4

OPERAT.
DATA

F4

ESC =
back

MEMO and
F1 or F3 /
F5 and ESC
= back

ESC =
back

ESC = back

= MODIFY DATA:
The existing data of the
dosing volume range can be
modified at a later stage:
Enter a smaller kg-DOS
volume, in 01 to 09 and a
larger kg-DOS volume in
07 to 09 and ENTER
In 10, enter a larger kgDOS volume and ENTER

ESC =
back

ESC = back

DOSING
PIPE
selection
and
ENTER

MEMO and
= REFERENCE DATA:
Transfer the displayed data of F1 or F3 /
the
REFERENCE
kg- F5
DIAGRAM or extend dosing
volume range:
Enter a smaller kg-DOS
volume in 01 to 03 and a
larger kg-DOS volume in
07 to 09 and ENTER
In 10, enter a larger kgDOS volume and ENTER

ESC = back

ESC = back

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

Version: 12.99 A

13 - 14

03.00

SETUP MODE: REGULATOR HEATING


ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
The access to the setup mode can be locked by a
code.

According to the actual WESTOMAT equipment, for


the temperature regulation of the furnace heating, an
internal or an external temperature regulator is
selected in the LOG of the Pro Dos DPC. If an
external temperature regulator is installed, this setup
mode is not available.
In this setup mode, the specific parameters of the
WESTOMAT
furnace
heating
regarding
its
functioning and regulation, i.e. monitoring and
regulation of the melt temperature, monitoring of the
furnace chamber temperature, are entered and
saved:

REGULATOR CONFIGURATION:

In
this
menu-supported
process,
the
parameters for the regulator configuration are
entered and saved.

FIRST WARM-UP:

In this menu-supported process, the warm-up


programmes for a cold start of the
WESTOMAT heating (of special importance
for the commissioning of the furnace) are
selected, started and/or terminated.
At cold start, the WESTOMAT must be
heated up over at least 24 hours to reach the
operating holding temperature of the melt
The NOMINAL operating temperature value is
preset at 650C in the Pro Dos DPC
programme; the settings for the required
holding temperature of the melt are made by
means of the help key / T.

TEMPERATURE REDUCTION:

In this menu-supported process, the weekdays


and times for the commencement and the end
of the weekend holding temperature
reduction of the melt are selected and saved.

ATTENTION:
The weekend reduction of the holding
temperature of the melt is only permitted, if there
are no objections from a metallurgical point of
view. The weekend temperature reduction is
activated in the setup menu OPERATING
MODES.

OPERATOR INTERFACE

STRUCTURE OF THE OPERATOR INTERFACE


0300-A1.DOC

14 - 14

03.00

WESTOMAT P ro Dos DPC


OPERATING MANUAL

Version: 12.99 A

DOSING CONTROL

SETUP MODE: REGULATOR HEATING


(continued)

Operator interface for: REGULAT OR - HEAT ING

F5

REGUL.
HEATING

F1

F5

F5

F5

INFO

ESC = back

with code
locking

ESC = back

with code
locking

ESC = back

with code
locking

ESC = back

ESC = back
REGUL.
CONFIG.

FIRST
WARM-UP

TEMP.
REDUCTION

Data entry for regulator configuration and


EMERGENCY HEATING and ENTER

Select warm-up
programme for FIRST
WARM-UP
(1 = ACTIVE / 0 = NOT
ACTIVE) and ENTER

MEMO and
F1 or F3 / F5

MEMO and
F1 or F3 / F5

Enter data (day, time for start and end


and reduction value) for temperature
reduction and ENTER

Operator interface for: ENTRY of M ELT T EM PERAT URES

Help key:

/T

Entry of HOLDING TEMPERATURE of MELT and of the limit


values for OVER / UNDERTEMPERATURE

ESC = back

MEMO and
F1 or F3 / F5

ESC =
back

ESC = FIRST
WARM-UP:
back
ACTIVE
and
subsequently:
automatically
in warm-up
operation

MEMO and
F1 or F3 / F5

ESC =
back

ESC =
back

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DOSING OPERATION (ON / OFF)

0400-B.doc

Version: 03.00 A

1-6

SWITCHING DOS ON / OFF GENERAL

04.00

The following example is based on a WESTOMAT


unit with Pro Dos DPC with the following equipment
and settings:
DC dosing contact with: ELECTRODE ... = ACTIVE
Filling level monitoring with: CELL ..... = ACTIVE
Internal temperature regulator: Holding temperature
of melt and melt temp. monitoring:
- Nominal value ................................. = 690 C
- Undertemperature (below nominal) .... = -10 C
- Overtemperature (above nominal) ........ = +15 C
Operating mode: TOP-STOP = ACTIVE
Operating mode: SYNCHRONIZATION
- with DIE CLOSED ............. = ACTIVE
Dosing pipe: No 1 - 80/24 mm .......... = used
Dosing volume: 5.75 kg ....................... = used
Prior to DOSING operation, complete the following:

***BASIC STATUS***
DOS. PIPE 80/24mm
= DATA LOG

10.03.00
13:34:57
/

HEATING
CELL IND.

TESTING:
- DC contact see also chapter 02.01
- Filling level monitoring see also chapter 02.03
- Temperature regulation see also chapter 02.04
In BASIC STATUS of the Pro Dos DPC:

ESC=back

Press help key

DATA DISPLAY

K02. DOSING CONTACT (DC) WITH:


0
2.5

and multi-function ke

= (Electrode = 1 / PneuCo = 0)
s = t5-DC (DC after deaeration)";

K03. LEVEL SCANNING WITH:


1 "
= (CELL = 1 / HPDE =
K04. TEMPERATURE REGULATION:
1
= (INTERN = 1 / EXTERN
1
= (C = 1 / F = 0)
FILL
LDH
CYCLE
LEVEL
SETUP
DATA

F 5 = SETUP

DATA and read setup LOG. Check functions for


K02, K03 and K04.

0)

Exit menu by pressing

ESC .

= 0)

ATTENTION

SETUP
DATA

For the DC contact, the hardware switch in the


switch cabinet must be set to the appropriate
position, in addition to the selection in the LOG.
s

***BASIC STATUS***
10.03.00
13:34:57
DOS. PIPE 80/24mm
ESC=back

HEATING
CELL IND.

TEMPERATURE
MELT
F. CHAMB.
ACTUAL
= 694C
= 723C
NOMINAL
= 695C
OVERTEMPERATURE =
15C
= 850C
UNDERTEMPERATURE =
10C
RUNNING TIME METER HEATING
FULL LOAD OPERATION
=
126:34/h
PARTIAL LOAD OPERATION
= 10942:43/h
MEMORY
ZURCK
= NEIN
EINGABE

TESTING of:
- Holding temperature of melt and melt monitoring
see also chapter 06.05:
- Nominal value ........................ = C
- Undertemperature (below nominal) . = C
- Overtemperature (above nominal) ... = C
In BASIC STATUS of the Pro Dos DPC:
Press help key

i/T

to activate INFO display and compare displayed


values with the die-specific settings.

Exit menu by pressing

ESC .

DOSING OPERATION (ON / OFF)

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SWITCHING DOS ON / OFF GENERAL


04.00

0400-B.doc

2-6

Version: 03.00 A

TESTING:
- Operating mode: TOP-STOP
- Operating mode: SYNCHRONIZATION
- see also chapter 02.05.
In BASIC STATUS of the Pro Dos DPC:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 80/24mm
,
INPUT,
ENTER
and
MEMO / ESC=back

F3 =

Press multi-function key

OPERATING MODES, enter settings for:

with TOP-STOP = 1

SYNCHRONIZATION
CLOSED = 1

SETUP OPERATING MODES


1 = with TOP-STOP
YES=1 NO=0
with

Exit menu by pressing

DCM

signal

DIE

ESC .

ATTENTION
In order to prevent unauthorised access, F3 =
OPERATING MODES can be locked by code.

0 = with LEVEL-SCANNING

YES=1 NO=0

1 = with SYNCHRONIZING to DCM-signal


DIE CLOSED 1
YES=1 N0=0
0 = with SYNCHRONIZING to DCM-signal
DIE READY TO INJECT 1 YES=1 N0=0
INFO

TESTING:
- Dosing pipe size
Compare actual dosing pipe size with the size
displayed in BASIC STATUS of the Pro Dos DPC
(top left display field).

ATTENTION
If the entered dosing pipe size does not correspond
with the actual size, the following might occur:
The dosing of an unsuitable volume, which
could result in the overfilling of the shot sleeve
(risk danger of FIRE)
Disturbances in the dosing process.

***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 80/24mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

DOSING CONTROL

TESTING:
- Dosing volume
- see also chapter 02.01.1.

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

In BASIC STATUS of the Pro Dos DPC


Press multi-function key

F4 =

Kg-DOS: NEW is the die-specific kg-volume.


Compare with entered value for kg-DOS and check
all associated values.

10.03.00 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 CELL IND.
DOS. PIPE 80/24mm
, INPUT, ENTER and MEMO / ESC=back

Kg-DOS-RANGE:

Exit menu press

ESC .

ATTENTION
If the entered kg-DOS value does not correspond
with the die-specific kg-volume, the following might
occur:

Overfilling of the shot sleeve (risk of FIRE)

Insufficient filling of the shot sleeve (risk of


damage to machinery and tools)

4.50 to 12.50 kg

5.75 kg = dosing volume (OFFLINE)


+ 0.00
kg = AUTO-increase up to 4.27
-0.45
kg = AUTO-decrease up to 3.25
-35.0 % = furnace chamber-CORRECTION
1.7
s = t5 - lag time
P-FD = 60 mbar / t4 = 0.31 s
INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DOSING OPERATION (ON / OFF)

SWITCHING DOS ON / OFF GENERAL


0400-B.doc

Version: 03.00 A

3-6

04.00

SWITCHING ON DOSING
***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 80/24mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s

The actual switching on of the dosing operation is


carried out in the BASIC STATUS of the Pro Dos
DPC:

Press multi-function key F 5 = DOSING and

external illuminated key DOS ON

switches I-08 to 1 = ON via an external switch


relays.

DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

Multi-function key

F2

F3

F4

F5

F 5 = DOSING

In BASIC STATUS
Press

F1

, which

F 5 = DOSING,

to change to F5-STATUS - querying of the


parameters for the status DISTURBANCES and the
closing status of the DCM DIE.
In F5-STATUS, the following queries and data are
displayed:

OFFLINE:
5.75kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 80/24mm
DISTURB.: FURNACE EMPTY / ESC=back

DIST. OPERATION FILLING LEVEL EMPTY:

Conditions for status DISTURBANCES, that


are displayed as ERRORS with operating
instructions
and
without
DISRUPTION
signalling
- In this example disruption FURNACE EMPTY

- MIN-furnace level is reached


- check filling level and REFILL
- acknowledgeable after removing fault
MODIFY
kg-DOS:
INFO
NEW
DATA
DOSING

OFFLINE:
5.75kg
10.03.00
HEATING
13:34:57
CELL IND.
DOS. PIPE: 80/24mm
Position error: I-24=1 / ESC=back

Closing position of the DCM DIE, displayed as


POSITION ERROR
- in this example non-conforming position of the
plunger (I-24 = 1)

I-24 PLUNGER IN BACK POSITION (DCM) ....


= 1
- PLUNGER was not moved:
- move PLUNGER compl. in FRONT- and
BACK into END POSITION!
MODIFY
kg-DOS:
INFO
NEW
DATA
DOSING

OFFLINE:
5.75kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 80/24mm
EXT-KEY DOS-ON /instruction/ ESC=back

After rectifying of all ERRORS / POSITION


ERRORS, the dosing operation must be continued.

Instruction for AUTO-DOSING OPERATION:


- switch DCM into AUTO!
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !
MODIFY
kg-DOS:
INFO
NEW
DATA
DOSING

The ERROR / POSITION ERROR indications


are automatically acknowledged as soon as the
cause of the disturbance is removed; the display
returns to MANUAL / AUTO mode.

DOSING OPERATION (ON / OFF)

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SWITCHING DOS ON / OFF GENERAL


04.00

4-6

0400-B.doc

Version: 03.00 A

DOSING CONTROL

EXAMPLE with TOP-STOP, DCM in MANUAL mode,


and DIE OPEN
By following the operating instructions in F5-STATUS
(display in MANUAL / AUTO mode) the conditions for
switching are established.

Illuminated key

DOS-ON

Illuminated key DOS-ON is activated (HOLD until


TOP-STOP = ACTIVE is signalled)
- see also chapter 02.05
- During activation, the indicator lamp DOS-READY
(O-22) is blinking

ATTENTION
If the illuminated key DOS-ON is released before
TOP-STOP is reached, the system is reset to F5STATUS and the POSITION ERROR TOP-STOP
is issued.

OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 80/24mm
TOP-STOP = activate
TOP-STOP = is being prepared
- this operational mode is selected
- hold external key DOS-ON
until TOP-STOP ready for operation!
MODIFY
INFO
DATA
DOSING

OFFLINE:
5.75kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 80/24mm
Position error: TOP-STOP / ESC=back
TOP-STOP = not operational
- this operational mode is not
selected
- hold external key DOS-ON
until TOP-STOP ready for operation!
INFO

After reaching TOP-STOP:


- Release of dosing operation ON, O-05 = 1 and
external switch relay is switched to auto-hold
- Display switches to DOSING MODE
- The indicator lamp DOS-READY (O-22) is not
blinking
- For MANUAL-DOS, the DCM DIE must be closed

MODIFY
DATA

OFFLINE:
5.75kg
DOS. PIPE: 80/24mm
CLOSE DCM-DIE
t6

kg-DOS:

NEW

DOSING

MANUAL
DOSING
CELL IND. ... END

t7

DCM-DIE

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO
MODIFY
DATA
DOSING

After closing of DCM DIE:


- Ready for operation for MANUAL-DOS

OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 80/24mm
DOSING by HAND = READY
t6

t7

DCM-DIE

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO
MODIFY
DOSING
DATA
by HAND

DOSING OPERATION (ON / OFF)

WESTOMAT ProDos DPC


OPERATING MANUAL

SWITCHING DOS ON / OFF GENERAL


0400-B.doc

DOSING CONTROL

Version: 03.00 A

5-6

04.00

EXAMPLE without TOP-STOP, DCM in MANUAL


mode, and DIE OPEN
By following the operating instructions in F5-STATUS
(display in MANUAL / AUTO mode) the conditions for
switching are established.
OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 80/24mm
Instruction / EXT.-KEY DOS-OFF

Instruction for AUTO-DOSING OPERATION:


- switch DCM into AUTO!
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !
MODIFY
INFO
DATA
DOSING

Illuminated key DOS-ON has been activated


- Release of dosing operation ON, O-05 = 1 and
external switch relay is switched to auto-hold.
- Display switches to DOSING MODE
- For MANUAL-DOS, the DCM DIE must be closed

The DCM DIE is being closed

The DCM DIE is being closed further

To DOSING by HAND:
I-19 DIE CLOSES (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

To DOSING by HAND:
I-19 DIE CLOSES (DCM) ........... = 1
I-20 DIE CLOSED (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ......... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 80/24mm
DOSING by HAND = READY
t6

t7

The DCM DIE is fully closed


- Ready for operation for MANUAL-DOS

DCM-DIE
DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO

MODIFY
DATA

DOSING
by HAND

OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 80/24mm
Position error: I-24=1 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM) ....
= 1
- PLUNGER was not moved:
- move PLUNGER compl. in FRONT- and
BACK into END POSITION!
MODIFY
INFO
DATA
DOSING

By SWITCHING ON of the dosing operation without


pressing the multi-function key F5, the unit is directly
switched to DOSING MODE:

Signal disruptions are signalled as DISRUPTIONS

If TOP-STOP is selected and signal status is not


disrupted, TOP-STOP is activated. After it has been
reached, the POSITION ERROR of the DCM DIE is
displayed
- in this example I-24 = 1.

DOSING OPERATION (ON / OFF)

SWITCHING DOS ON / OFF GENERAL


0400-B.doc

6-6

04.00

SWITCHING OFF DOSING


To SWITCH OFF dosing operation:

Press key ESC - back to BASIC STATUS, or


Press ext. key
F5-

DOS-OFF to return to

STATUS. The querying of the signal statuses


(regarding ERRORS and POSITION ERRORS)
continues to be active continue:

Press key ESC - back to BASIC STATUS.

ATTENTION
After the switching off and return to BASIC
STATUS, an already established ready-foroperation status is reset to MANUAL-DOS and the
preparation must be repeated.

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DOSING OPERATION (ON / OFF)

0401-B.doc

Version: 03.00 A

1-2

SWITCHING MANUAL-DOS ON / OFF

04.01

The MANUAL DOSING mode is activated, if the control


is not set to AUTO (-AUTO), DOSING OPERATION is
switched on, and the DCM-AUTO signal is not
switched (I-18 = 0).
***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 100/35mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

EXAMPLE FOR SWITCHING ON


- see also chapter 04.00

F1

F2

F3

F4

SETUP EXAMPLE:
The Pro Dos DPC is set up as follows:
Dosing pipe 100/35 mm ............. = ACTIVE
Dosing volume = 27.65 kg ............ = ACTIVE
Operating mode TOP-STOP ......... = ACTIVE
Filling level detection with CELL ... = ACTIVE
Internal temperature REGULATOR ... = ACTIVE

F5

In BASIC STATUS,
press multi-function key

F5

until

and status free of ERRORS and POSITIONERRORS is reached:


OFFLINE:
27.65kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
EXT-KEY DOS-ON /instruction/ ESC=back

Display changes to F5-STATUS displaying the


instruction form for DOSING

Instruction for AUTO-DOSING OPERATION:


- switch DCM into AUTO!
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !
MODIFY
kg-DOS:
INFO
DATA
NEW
DOSING

OFFLINE:
27.65kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
EXT-KEY DOS-ON /instruction/ ESC=back

By activating the manual DCM DIE CLOSE


function, the display automatically changes to
display the CLOSE STATUS

By activating the manual DCM DIE CLOSE


function, the display automatically changes to
display the CLOSE STATUS

To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
- DCM-DIE to be closed in
MANUAL POSITION!
INFO
MODIFY
kg-DOS:
DATA
NEW
DOSING

OFFLINE:
27.65kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
EXT-KEY DOS-ON /instruction/ ESC=back
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!
INFO
MODIFY
kg-DOS:
DATA
NEW
DOSING

DOSING OPERATION (ON / OFF)

WESTOMAT P ro Dos DPC


OPERATING MANUAL

MANUELL-DOS EIN-/ AUS-SCHALTEN

0401-B.doc

2-2

04.01

Version: 03.00 A

OFFLINE:
27.65kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
EXT-KEY DOS-ON /instruction/ ESC=back
At manually closed DCM die, the display
automatically changes to indicate READY FOR
OPERATION; if TOP-STOP mode is not selected

To DOSING by HAND:
DCM-DIE = READY FOR DOSING!
INFO

DOSING CONTROL

Press external illuminated key

DOS-ON

If TOP-STOP mode is selected, it is


automatically activated
- The pressure increase in the furnace chamber
ensures that the melt rises in the dosing pipe
to DC
- see also chapter 02.05 Activating TOPSTOP

When TOP-STOP is reached, the unit is


ready for operation in MANUAL-DOS

A DOSING process is started by pressing


Multi-function key

MODIFY
DATA

kg-DOS:
NEW
DOSING

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
TOP-STOP = activate
TOP-STOP = is being prepared
- this operational mode is selected
- hold external key DOS-ON
until TOP-STOP ready for operation!
MODIFY
INFO
DATA
DOSING

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 100/24mm
DOSING by HAND = READY
t6

t7

DCM-DIE

F5

- Dosing process see chapter 02.01.

TS=

DC
t2

t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO
MODIFY
DOSING
DATA
by HAND

F1

If TOP-STOP is not selected, the unit is


immediately ready for operation in MANUALDOS
A DOSING process is started by pressing
Multi-function key

F3

F4

F5

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 100/24mm
DOSING by HAND = READY
t6

F5

F2

t7

DCM-DIE

- Dosing process see chapter 02.01.


DC
t2

t3

t4

t5

To SWITCH OFF dosing operation:

WESTOMAT: AVAILABLE = 890 kg MELT

INFO

Press key ESC - back to BASIC STATUS, or


press external key
F5-STATUS and

MODIFY
DATA

DOS-OFF to return to

Press key ESC - back to BASIC STATUS.

F1

F2

F3

DOSING
by HAND

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DOSING OPERATION (ON / OFF)

0402-A.doc

Version: 12.99 A

1-2

SWITCHING AUTO-DOS ON / OFF

04.02

The AUTO-DOSING mode is activated, if, after the


switching on of the dosing operation in the Pro Dos
DPC, the DCM control is selected in -AUTO or in
AUTO (I-18 = 1) mode.

SETUP EXAMPLE:
The Pro Dos DPC is set up as follows:
Dosing pipe 100/35 mm ................. = ACTIVE
Dosing volume = 27.65 kg ............... = ACTIVE
Operating mode TOP-STOP ............. = ACTIVE
Filling level detection with CELL ...... = ACTIVE
Internal temperature REGULATOR ... = ACTIVE

SWITCHING ON AUTO-DOS
OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
instruction / EXT.-KEY DOS-OFF

After starting in MANUAL-DOS by means of:

Instruction for AUTO-DOSING OPERATION:


- switch DCM into AUTO!
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !
MODIFY
INFO
DATA
DOSING

OFFLINE:
27.65kg
DOS. PIPE: 100/35mm

pressing external illuminated key DOS-ON

The DCM control is in MANUAL mode

The DCM die is open and the plunger is in back


position

TOP-STOP is activated

Set DCM control to -AUTO or AUTO mode:

The ProDos DPC switches to AUTO-DOS ...

AUTO
DOSING
CELL IND. ... ON

ON and

t6

t7

t8

DCM-DIE
t9

DC

the visualisation field in the display is switched


to the display for ASYNCHRON-AUTO-DOS

ATTENTION

TS=

t2

until

DOSING MODE is activated:

t3

t4

WESTOMAT: AVAILABLE = 890 kg MELT


MODIFY
INFO
DATA

If the DCM-AUTO is selected while the ProDos


DPC is in another mode than the above, the
position error I-18 = 1 / AUTO-DCM is displayed.

t5

SWITCHING OFF AUTO-DOS


By switching back DCM-AUTO (I-18 = from 1 to 0) the
Pro Dos DPC changes to MANUAL mode:

The querying of the signal status remains activated.


ATTENTION
If the DCM-AUTO is reset during an AUTO-dosing
cycle (in AUTO-DOS ... RUN), the DISTURBANCE:
AUTO DCM is signalled.

DOSING OPERATION (ON / OFF)

SWITCHING AUTO-DOS ON / OFF


04.02

2-2

0402-A.doc

blank page

Version: 12.99 A

WESTOMAT P ro Dos DPC


DOSING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES

0500-B.doc

Version: 03.00 A

1-6

DISTURBANCES - GENERAL

05.00

The operating processes of the WESTOMAT are


controlled, regulated and monitored by the Pro Dos
DPC. Non-conforming signal status are indicated as
disturbances.
BASIC STATUS
In BASIC STATUS, only the operating status of the:

FURNACE HEATING if internal regulator = ACTIVE

CELL FILLING LEVEL IND. .. ... if CELL = ACTIVE

are monitored and only the related disturbances are


signalled.
The monitoring of the FURNACE HEATING (in all
operating modes of the Pro Dos DPC) switches the
disturbance HEATING ALARM and also O-08 (from 1
to 0) see chapter 05.01.
F5-STATUS
When starting the unit from BASIC STATUS by means
of:

Pressing key F 5 = DOSING

The monitoring system is queried and any


disturbances are indicated in the display as ERRORS.
Display switches to F 5-STATUS.
STARTING by means of ... KEY

DOS-ON

At starting the unit by means of the external


illuminated key DOS-ON (input I-08 = 1), the
monitoring for disturbances is activated. Detected
disturbances are indicated in the display as ERRORS.
The display changes to DISTURBANCE MODE. The
visualisation field remains unaltered, while the output
signals are switched to the respective disturbance and
signalling is activated:

HORN is activated (O-02 = 1)

Indicator lamp DISTURBANCE is blinking (O-24 =


1/0).

DOSING STATUS
In the dosing process (DOSING ... RUN), critical
disturbances result in the termination of the dosing and
the respective DISTURBANCE is indicated in the
display. The display changes to DISTURBANCE
MODE. The visualisation field remains unaltered, while
the output signals are switched to the respective
disturbance and signalling is activated:

HORN is activated (O-02 = 1)

Indicator lamp DISTURBANCE is blinking (O-24 =


1/0).

Disturbance METAL SUPPLY at DCM (O-13 = 1).

DISTURBANCES

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DISTURBANCES - GENERAL
2-6

05.00

0500-B.doc

Version: 03.00 A

DOSING CONTROL

SWITCHING AND ACKNOWLEDGEMENT IN THE


EVENT OF DISTURBANCES
If a disturbance occurs while a dosing cycle is running
(MANUAL-DOS or AUTO-DOS ... RUN), the display
changes to the respective DISTURBANCE MODE:

The dosing operation is interrupted, while the


heating and the filling level indication by CELL
remain active

Output DISTURBANCE METAL SUPPLY, O-13 =


switches from 0 to 1

The INSTRUCTION line shows the respective error


message and is blinking

The visualisation field freezes at the moment of the


disturbance.
EXAMPLE

in AUTO-SYNCHRON mode and during active


metal supply, the disturbance EMERGENCY
STOP DCM is activated:

The Pro Dos DPC is set up as follows:


Dosing pipe 100/35 mm .................. = ACTIVE
Dosing volume = 24.55 kg .............. = ACTIVE
Filling level detection with CELL .. = ACTIVE
Internal temperature REGULATOR ..... = ACTIVE
Operating mode TOP-STOP .............. = ACTIVE
OFFLINE:
24.55 kg
21.07.99
13:34:57
DOS. PIPE 100/35mm
DISTURB.-06: EMERGENCY STOP DCM
t6

Display switches to DISTURBANCE mode.

t8

t7

DCM-DIE
TS=

t9
t1

t2

p= 99.42 mb

DC
t3

nt= 6379

t4

t5

at=

DIST.
INFO

HEATING
CELL IND.

DOSING

Press key F 1 = DISTURB. INFO


to call up the operating instructions:

The operating instructions are displayed

O-02 (HORN) switches from 1 to 0

Key F 1
available

= DISTURB. ACKNOWL. is

In the event of status errors where the cause


of the disturbance cannot be reset:

The description changes from


DISTURBANCE to ERROR:
EMERGENCY STOP DCM:
- ERROR display is automatically
acknowledged by removing the cause
of the ERROR
In the event of process disturbances:

The term DISTURBANCE in the display is


replaced by the actual position error.
e.g.:
- TOP-STOP or
- DCM-DIE (signal).
ATTENTION
Process disturbances can be immediately
acknowledged, while status disturbances can only
be acknowledged after the cause of it has been
removed.

OFFLINE:
24.55 kg
21.07.99
13:34:57
DOS. PIPE 100/35mm
DISTURB.-06: EMERGENCY STOP DCM

HEATING
CELL IND.

DIST. of signal EMERGENCY STOP DCM:


- EMERGENCY STOP key is used within
area of die-casting machine (I-03 = 0)
- check and remove fault!
- acknowledgeable after removing fault
DIST.
DOSING
ACKNO.

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES - GENERAL
0500-B.doc

Version: 03.00 A

3-6

05.00

Disturbances can be acknowledged as follows:


Press blinking illuminated key
DISTURB. ACKNOWL.

- operating instructions are not displayed


or:

Press key F 1 = DISTURB. ACKNOWL.


- after display of operating instructions

OFFLINE:
27.65kg
21.07.99 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
Position error: TOP-STOP / ESC=back
TOP-STOP = not operational
- this operational mode is selected
- hold external key DOS-ON
until TOP-STOP ready for operation!
INFO

MODIFY
DATA

The display switches to F5-STATUS (with indication


of POSITION ERROR)
By acknowledging a disturbance in the dosing
operation, it is entered in the ERROR HISTORY list
(incl. description, date and time) see chapter 06.01.
DOSING OPERATION AFTER A DISTURBANCE

kg-DOS:

NEW

DOSING

After a disturbance, the status of DOS-ON is switched


off I-08 = from 1 to 0.
After the acknowledgement of a disturbance (after
disturbance removal for status disturbances), the
display changes to F 5-STATUS - the operating
instructions for switching on are displayed.
In F5-STATUS, proceed to:

Press illuminated key


ON

DOS-

to restart the dosing operation


or:

Press key ESC - back to BASIC STATUS.


of the Pro Dos DPC.

IMPORTANT - after a disturbance in the dosing cycle:

Always read the operating instructions (press INFO


key) and remove cause of disturbance

Allow melt in the shot sleeve of the DCM to solidify

OPEN DIE in DCM mode MANUAL

Use the DCM plunger to push the (hot) aluminium


block from the shot sleeve

Start the dosing operation by means of the external


illuminated switch DOS-ON and activate the
selected operating mode TOP-STOP

Set DCM control to -AUTO or AUTO and start


new cycle:

The first dosing cycle is carried out in AUTOASYNCHRON. mode, and synchronization is
activated after a sequence of n AUTO dosing
processes (see LOG entry K11).

DISTURBANCES

DISTURBANCES - GENERAL
05.00

4-6

0500-B.doc

TYPES OF DISTURBANCES
The following disturbances result from the monitoring
of the operation of the individual input signals:

STATUS DISTURBANCES ................ see 05.01:

These disturbances are signalled in the event of


incorrect status (signal switch status or signal
level)

The dosing operation can only be resumed after


the cause of the disturbance has been removed

PROCESS DISTURBANCES of the WESTOMAT - see


05.02:

These disturbances are signalled in the event of


incorrect status of the WESTOMAT signals (signal
switch status or signal level)

Dosing operation can be resumed immediately


after acknowledgement of the disturbance

PROCESS DISTURBANCES of the DCM see 05.03:

These disturbances are signalled in the event of


incorrect switch status or processes of the DCM
DIE signals

Dosing operation can be resumed immediately


after acknowledgement of the disturbance

Disturbances sorted by TYPE and DISTURBANCE


NO:

STATUS DISTURBANCES (chapter 05.01)

DISTURB.-01: HEATING ALARM


DISTURB.-02: MEAS. PRESS. CONVERTER
DISTURB.-03: LOAD CELL
DISTURB.-04: FURNACE EMPTY
DISTURB.-05: EMERGENCY STOP WESTOMAT
DISTURB.-06: EMERGENCY STOP DCM
DISTURB.-07: PneuCo
DISTURB.-08: DOSING CONTACT
DISTURB.-09: UNDERTEMPERATURE

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES

DISTURBANCES - GENERAL
0500-B.doc

Version: 03.00 A

5-6

05.00

... STATUS DISTURBANCES (continued)


DISTURB.-10: UNDERTEMPERATURE
DISTURB.-11: OVERTEMPERATURE
DISTURB.-12: OVERTEMPERATURE
DISTURB.-13: CLEANING DOOR
DISTURB.-14: OVERPRESS. FURN. CHAMBER
DISTURB.-15: CAST POSITION
DISTURB.-16: HEATING ON
DISTURB.-17: TEMP FURNACE CHAMBER
DISTURB.-18: REFILL COVER NOT CLOSED
DISTURB.-19: I-08 PERMANENT CONTACT

WESTOMAT - PROCESS
DISTURBANCES (chapter 05.02)

DISTURB.-30: PREMAT. DC=DOSING CONTACT


DISTURB.-31: DOSING CONTACT NOT REALIZED
DISTURB.-32: DOSING CONTACT NOT BACK
DISTURB.-33: DOSING CONTACT DROPPED OFF
DISTURB.-34: ADD. DC=DOSING CONTACT
DISTURB.-35: DOSING CONTACT AFTER END
DISTURB.-36: DOSING CONTACT AFTER END
DISTURB.-37: DOSING OFF
DISTURB.-38: TOP-STOP
DISTURB.-39: TOO MUCH LEAKING LOSSES
DISTURB.-40: TOO MUCH LEAKING LOSSES
DISTURB.-41: OPERATION LEVEL EMPTY

DISTURBANCES

DISTURBANCES - GENERAL
05.00

6-6

0500-B.doc

... WESTOMAT PROCESS DISTURBANCES (cont.)


DISTURB.-42: OVERPRESS. FURN. CHAMBER
DISTURB.-43: FEED PRESSURE TOO HIGH
DISTURB.-44: FEED PRESSURE TOO LOW
DISTURB.-45: DC-PRESSURE TOO LOW
DISTURB.-46: DC-PRESSURE TOO HIGH
DISTURB.-47: DEAERATION FURNACE
DISTURB.-48: TOTAL DOSING TIME

DCM PROCESS DISTURBANCES


(chapter 05.03)

DISTURB.-60: AUTO-OPERATION DCM


DISTURB.-61: DCM-DIE CLOSES
DISTURB.-62: DCM-DIE CLOSED 1
DISTURB.-63: DCM-DIE CLOSED 2
DISTURB.-64: DCM-DIE READY F.INJECT. 1
DISTURB.-65: DCM-DIE READY F.INJECT. 2
DISTURB.-66: PLUNGER IN BACK POSIT.
DISTURB.-67: DCM PLUNGER NOT MOVED
DISTURB.-68: DC BEFORE DCM-DIE CLOSED
DISTURB.-69: DC BEFORE DCM-DIE CLOSED
DISTURB.-70: DISCONT. SYNCHRO OPERAT.
DISTURB.-71: DCM-DIE READY F.INJECT.1 = 0

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0501-B.doc

Version: 03.00 B

1-6

STATUS DISTURBANCES

05.01

BASIC STATUS
In the Pro Dos DPC BASIC STATUS, only the
monitoring of the CELL filling level system and of the
furnace temperature is activated:

DISTURBANCE of the CELL filling level


indication system
The disturbance results from the monitoring of the
limit values of the mA-signals 4 to 20 of AI-04, if I <
4 mA or I > 20 mA:

The fill level lamps start blinking and the display


is blank

Inspect load cell (CELL) and circuit and repair, if


necessary

Acknowledge disturbance

DISTURBANCE 01: HEATING ALARM


This disturbance occurs after the switching on of
the ProDos DPC and if the configuration data is
corrupted:

Re-enter configuration data see chapter


07.03.1.

The disturbance results from a plausibility query of


the mV input signals (failure of thermocouple):

AI-01 = Thermocouple melt

AI-02 = Thermocouple furnace chamber

and the monitoring of the melt temperature (saved


limit values):

AL-O-08-HEATING OVERTEMPERATURE

AL-O-08-HEATING UNDERTEMPERATURE

and O-08 = from 1 to 0, if:

Press F1 = DISTURB. INFO

DISTURB.-01: HEATING ALARM

a thermocouple failure is detected

The NOMINAL melt temperature is above the


limit
value
for
AL-O-08-HEATING
OVERTEMPERATURE

Disturbance of MELT temperature:


- thermocouple-melt
- thermocouple-chamber
- heating circuit

... - check and remove fault!


DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

The heating is switched OFF

The NOMINAL melt temperature is below the


limit
value
for
AL-O-08-HEATING
UNDERTEMPERATURE

The heating is not switched off

Inspect the connections AI-01 = melt and AI-02


= furnace chamber and the thermocouples and
repair, if necessary

The disturbance is automatically acknowledged


after a lag time (of up to approx. 5 minutes).

DISTURBANCES

STATUS DISTURBANCES
05.01

2-6

0501-B.doc

WESTOMAT P ro Dos DPC


OPERATING MANUAL

Version: 03.00 B

DOSING CONTROL

DOSING MODE after


WITCHING ON BY MEANS OF KEY

DOS-ON

At the switching on of the Pro Dos DPC by means of


the external illuminated key DOS-ON (I-08 = from 0 to
1) and in DOSING MODE (I-08 = 1), the monitoring of
certain input status is activated.
In the event of non-compliant signal status, a STATUS
DISTURBANCE is signalled. This disturbance can only
be acknowledged after the cause has been removed.
In the dosing process (DOSING ... RUN), critical
disturbances result in the termination of the dosing
process. In such events, a STATUS DISTURBANCE is
indicated on the display.
The priority of the status queries corresponds to the
list below. In the event of several disturbances, the
one with the highest priority is displayed.
ATTENTION
The evaluation of the cause for a disturbance and
any repairs must be carried out only by specifically
trained staff.
Always comply with the safety instructions in the
operating manual.

DISTURBANCE 01: HEATING ALARM


- see equivalent disturbance in basic status

In DOSING ... RUN not critical; only signalled


after completion of cycle.

DISTURBANCE 02: MEASURING PRESSURE


CONVERTER
The disturbance results from the monitoring of the
limit values of the mA-signals 4 to 20 of AI-03, if I <
4 mA or I > 20 mA:

Inspect furnace chamber measuring pressure


converter and circuit and repair, if necessary

Acknowledge disturbance

DISTURBANCE 03: LOAD CELL


the disturbance results from the monitoring of the
limit values of the mA-signals 4 to 20 of AI-03, if I <
4 mA or I > 20 mA:

The filling level lamps start to blink

Inspect load cell (CELL) and circuit and repair, if


necessary

Acknowledge disturbance

Press F1 = DISTURB. INFO

DISTURB.-02: MEAS. PRESS. CONVERTER


DIST. of signal MEASURING-PRESSURE CONV:
- mA-Signal of AI-03 too SMALL
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Press F1 = DISTURB. INFO

DISTURB.-03: LOAD CELL


DIST. of signal LOAD CELL (SCAN):
- mA-Signal of AI-04 too SMALL
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES

STATUS DISTURBANCES
0501-B.doc

Press F1 = DISTURB. INFO

Version: 03.00 B

The disturbance results from the monitoring of the


min. filling level (stored mA-signal of CELL) for the
operating filling level EMPTY, if I-AI-04 < I-EMPTY :

DIST. OPERATION FILLING LEVEL EMPTY:


- MIN-furnace filling level is reached
- check filling level and REFILL

Press F1 = DISTURB. INFO

DIST. of signal EMERGENCY STOP WESTOMAT:


- within WESTOMAT range, EMERGENCY STOP
key is used (I-02 = 0)
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

DISTURB.-06: EMERGENCY STOP DCM

Disturbance with termination of dosing process


Inspect filling level in furnace and refill, if
necessary

Acknowledge disturbance

DISTURBANCE 05: EMERGENCY STOP


WESTOMAT
The disturbance results from the monitoring of the
switch status of I-02 = 1, if I-02 = from 1 to 0:

DISTURB.-05: EMERGENCY STOP WESTOMAT

Press F1 = DISTURB. INFO

- acknowledgeable after removing fault


DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Disturbance with termination of dosing process

After evaluation of the cause for the


EMERGENCY STOP, unlock the EMERGENCY
STOP key of the WESTOMAT control

Acknowledge disturbance

DISTURBANCE 06: EMERGENCY STOP DCM


The disturbance results from the monitoring of the
switch status of I-03 = 1, if I-03 = from 1 to 0:

Disturbance with termination of dosing process

After evaluation of the cause for the


EMERGENCY STOP, unlock the EMERGENCY
STOP key of the DCM control

DIST. of signal EMERGENCY STOP DCM:


- EMERGENCY STOP key is used within
area of die-casting machine (I-03 = 0)
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

05.01

DISTURBANCE 04: FURNACE EMPTY


with CELL

DISTURB.-04: FURNACE EMPTY

3-6

Acknowledge disturbance

DISTURBANCE 07: PneuCo


The disturbance results from the monitoring of the
switch status of I-16 = 1, if I-16 = from 1 to 0:

Press F1 = DISTURB. INFO

Disturbance with termination of dosing process

Inspect PneuCo dosing contact monitoring


system and repair, if necessary

DISTURB.-07: PneuCo
DIST. of signal MONITORING PneuCo:
- disturb. of dosing contact detection
with PneuCo (I-06 = 0)
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Acknowledge disturbance

DISTURBANCES

STATUS DISTURBANCES
05.01

4-6

0501-B.doc

DISTURBANCE 08: DOSING CONTACT


The disturbance results from the monitoring of the
switch status of I-01 = 0, if I-01 = from 0 to 1:

In DOSING ... RUN not monitored


Inspect dosing contact monitoring system
(PneuCo or ELECTRODE) and repair, if
necessary
Acknowledge disturbance

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

Press F1 = DISTURB. INFO

DISTURB.- 08: DOSING CONTACT


Disturbance of signal DOSING CONTACT
(DC):
- permanent contact within area of (DC)
dosing contact detection (I-01 = 1)
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

DISTURBANCE 09: UNDERTEMPERATURE

With internal regulator:

The disturbance results from the monitoring of a


limit value of the melt temperature, if XC < W C
C-UNDERTEMPERATURE-MELT:

Press F1 = DISTURB. INFO

DISTURB.-09: UNDERTEMPERATURE
DISTURBANCE UNDERTEMPERATURE MELT:

In DOSING ... RUN not critical; only signalled


after completion of cycle.

signal (AI-01) has undershot limiting


value MINIMUM

The furnace heating heats the melt to a


temperature above the min. temperature

- check and WARM-UP !


- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Acknowledge disturbance

DISTURBANCE 10: UNDERTEMPERATURE

With external regulator:

The disturbance results from the monitoring of the


switch status of I-04 = 1, if I-04 = from 1 to 0:

In DOSING ... RUN not critical; only signalled


after completion of cycle.

Acknowledge disturbance

DISTURBANCE UNDERTEMPERATURE MELT:


- external regulator signals undertemperature melt (I-04 = 0)
- check and WARM-UP !
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

With internal regulator:

The disturbance results from the monitoring of a


limit value of the melt temperature, if XC > WC
+ C-OVERTEMPERATURE-MELT:

Press F1 = DISTURB. INFO

DISTURB.-10: UNDERTEMPERATURE

The furnace heating heats the melt to a


temperature above the min. temperature and I04 = from 0 to 1

DISTURBANCE 11: OVERTEMPERATURE

In DOSING ... RUN not critical; only signalled


after completion of cycle.
Wait until melt has reached a temperature
below the max. temperature (furnace heating =
OFF)
Acknowledge disturbance

Press F1 = DISTURB. INFO

DISTURB.-11: OVERTEMPERATURE
DISTURBANCE OVERTEMPERATURE MELT:
signal (AI-01) has exceeded the temp.
limiting value MAXIMUM
- check and let melt COOL !
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

STATUS DISTURBANCES
0501-B.doc

Press F1 = DISTURB. INFO

DISTURB.-12: OVERTEMPERATURE

Version: 03.00 B

5-6

05.01

DISTURBANCE 12: OVERTEMPERATURE


With external regulator:

DISTURBANCE OVERTEMPERATURE MELT:

The disturbance results from the monitoring of the


switch status of I-05 = 1, if I-05 = from 1 to 0:

- external regulator signals overtemperature of melt (I-05 = 0)

In DOSING ... RUN not critical; only signalled


after completion of cycle.

Wait until melt has reached a temperature


below the max. temperature (furnace heating =
OFF)

- check and let melt COOL !


- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Acknowledge disturbance

DISTURBANCE 13: CLEANING DOOR

Press F1 = DISTURB. INFO

DISTURB.-13: CLEANING DOOR


DISTURBANCE of signal CLEANING DOOR:
- lim-switch of cleaning door (I-06=0)
signalize NOT CLOSED
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

The disturbance results from the monitoring of the


switch status of I-06 = 1, if I-06 = from 1 to 0:

Disturbance with termination of dosing process

Close the open solenoid lock of the cleaning


door (or repair, if damaged)

Acknowledge disturbance

DISTURBANCE 14: OVERPRESSURE FURNACE


CHAMBER
The disturbance results from the monitoring of the
switch status of I-07 = 1, if I-07 = from 1 to 0:

Press F1 = DISTURB. INFO

DISTURB.-14: OVERPRESS. FURN. CHAMBER

Disturbance with termination of dosing process

Evaluate the cause for the increased pressure


in the furnace chamber and inspect furnace
chamber pressure switch (replace, if damaged)

DIST.of FURNACE-CHAMBER PRESS.WATCH DOG:


- watch dog (I-07) signalize EXCESSIVE
PRESSURE within furnace chamber

Acknowledge disturbance

- check and remove fault!


- acknowledgeable after removing fault
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 15: CAST POSITION


The disturbance results from the monitoring of the
switch status of I-09 = 1, if I-09 = from 1 to 0:

Disturbance with termination of dosing process

Check the limit switch operation (repair, if


damaged)

Press F1 = DISTURB. INFO

DISTURB.-15: CAST POSITION


DIST. of signal FURNACE IN CAST POS:
- (I-09=0) lim-switch FURNACE in CASTPOSITION not activated
- check and remove fault!
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Acknowledge disturbance

DISTURBANCES

WESTOMAT P ro Dos DPC


OPERATING MANUAL

STATUS DISTURBANCES
6-6

05.01

0501-B.doc

DISTURBANCE 16: HEATING ON


The disturbance results from the monitoring of the
switch status of I-15 = 1, if I-15 = from 1 to 0:

In DOSING ... RUN not critical; only signalled


after completion of cycle.

Evaluate the cause for the switching off of the


furnace heating and switch on heating

Acknowledge disturbance

Version: 03.00 B

DOSING CONTROL

Press F1 = DISTURB. INFO

DISTURB.- 16 HEATING ON
Disturbance of signal HEATING ON:
- circuit for HEATING ON (I-15 = 0)
is not active
check and switch on !
- acknowledgeable after removing fault
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

DISTURBANCE 17: TEMPERATURE FURNACE


CHAMBER
With internal regulator:
The disturbance results from the monitoring of the
max. value of the AL3 furnace chamber
temperature, if the furnace chamber temperature
(AI-02) exceeds this limit value:

In DOSING ... RUN not critical; only signalled


after completion of cycle.

Evaluate the cause for the disturbance


(standard temperature for AL3 furnace chamber
= 875C) and carry out repair, if necessary

Press F1 = DISTURB. INFO

DISTURB.-17: TEMP FURNACE CHAMBER


DIST. OVERTEMPERATURE FURNACE CHAMBER:
signal (AI-02) has exceeded limiting
value MAXIMUM (for AL3)
check thermocouple MELT and FURNACE
CHAMBER and compensation line
- check difference between REGULAT.-AL3
and melt-temp-NOM.-VALUE (min+100C)
and modify if necessary

Acknowledge disturbance

- acknowledgeable after removing fault


DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

DISTURBANCE 18: REFILL COVER NOT


CLOSED
The disturbance only occurs in the setup
procedures for P/t-MIN-MEASURING and kgDIAGRAM / REFERENCE VOLUMES based on the
monitoring of I-14 = 0, if I-14 = 1 and if the external
illuminated key DOS-ON is activated (I-08 = from 0
to 1):

Close refill cover

Acknowledge disturbance

Press F1 = DISTURB. INFO

DISTURB.-18: REFILL COVER NOT CLOSED


DISTURBANCE of signal
REFILL COVER (I-14 = 1):
- in this SETUP MODE, refill cover
should be closed !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

ERROR: I-08 PERMANENT CONTACT


This ERROR results after the switching on of the
ProDos DPC and is based on the monitoring of
the switch status for I-08 = 0, if I-08 = 1:

Inspect switch relay (replace, if necessary)


After elimination of the error (I-08 = from 1 to
0), the error is automatically acknowledged.

Press F1 = DISTURB. INFO

***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 80/24mm
ERROR: I-08 PERMANENT CONTACT

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0502-B.doc

Version: 03.00 A

1-8

PROCESS DISTURBANCES AT
WESTOMAT

05.02

In DOSING MODE (DOSING ON, ... END and ...


RUN), the WESTOMAT disturbances are based on
the monitoring of the Pro Dos DPC input signals.
The disturbances can be acknowledged and are not
prioritized so that the first occurring event results in a
disturbance.
The DISTURBANCE results in the termination of the
dosing process and is subsequently automatically
acknowledged.
ATTENTION
The inspection of the cause of a disturbance and
any repairs must be carried out only by specifically
trained staff.
Always comply with the safety instructions in the
operating manual.

DISTURBANCE 30: PREMATURE


DOSING CONTACT
In DOSING ... RUN, the disturbance results from
the monitoring of the switch status I-01 = from 0 to
1, if:

Press F1 = DISTURB. INFO

DISTURB.-30: PREMAT. DC=DOSING CONTACT


DIST. due signal error DOS-CONT. (I-01):
- DOSING-CONTACT (DC) prematurely
- check DC-detection at dosing pipe and
- remove fault!
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

I-01 = from 0 to 1 (prematurely), which is


switched with the PRESSURE START to DC
MIN. monitoring time. Evaluate cause and
rectify. Possible causes are:

metal residue in the dosing pipe

metal feed not carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DISTURB.-31: DOSING CONTACT NOT REALIZED

DISTURBANCE 31: DOSING


CONTACT NOT REALIZED
In DOSING ... RUN, the disturbance results from
the monitoring of the switch status I-01 = from 0 to
1 of the DC, if:

DIST. due signal error DOS-CONT. (I-01):


- DOS-CONT. (DC) was not executed
- at dosing feed:
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
- check DC-detection at dosing pipe
- and remove fault!
- if no dosing feed:
- clogging of dosing pipe check and
- remove fault!
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

I-01 = from 0 to 1 (prematurely), which is


switched with the PRESSURE START to DC
MAX. monitoring time. Evaluate cause and
rectify. Possible causes are:

insufficient contact of the electrode with the


+ 24 V DC voltage
electrode not in scanning position

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCES

PROCESS DISTURBANCES AT WESTOMAT


2-8

05.02

0502-B.doc

Version: 03.00 A

DISTURBANCE 32: DOSING CONTACT NOT BACK


In DOSING ... RUN with electrode DC monitoring,
the disturbance results from the monitoring of the
switch status I-01 = from 1 to 0, if:

jammed drive cylinder of the sensor device

failure of the solenoid valve of the drive


cylinder

metal feed already carried out.

Acknowledge disturbance.

DOSING CONTROL

Press F1 = DISTURB. INFO

DISTURB.-32: DOSING CONTACT NOT BACK


DIST. due signal error DOS-CONT. (I-01):
- DC has not been switched back during
metal feed

during the monitoring time, I-01 = from1 to 0 is


not switched. Evaluate cause and rectify.
Possible causes are:

WESTOMAT P ro Dos DPC


OPERATING MANUAL

- check DC-detection on dosing pipe and


remove fault!
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 33: DOSING CONTACT


DROPPED OFF
In DOSING ... RUN with PneuCo DC monitoring,
the disturbance results from the monitoring of the
switch status I-01 = 1, if:

DIST. due signal error DOS-CONT. (I-01):

during the dosing time, I-01 = from 1 to 0 is


switched. Evaluate cause and rectify. Possible
causes are:

DISTURB.-33: DOSING CONTACT DROPPED OFF


- DC dropped during metal feed and before deaeration
- check DC-detection on dosing pipe and
- check dosing pipe for clogging and
remove clogging!

failure of PneuCo

metal feed already carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 34: ADDITIONAL DOSING


CONTACT
In DOSING ... RUN with electrode DC monitoring,
the disturbance results from the monitoring of the
switch status I-01 = 0, if:

during the dosing time, a repeated switching I01 = from 0 to 1 is carried out. Evaluate cause
and rectify. Possible causes are:

incorrect setting
scanning position

failure of the solenoid valve of the drive


cylinder

of

the

metal feed already carried out.

Acknowledge disturbance.

electrode

in

Press F1 = DISTURB. INFO

DISTURB.-34: ADD. DC=DOSING CONTACT


DIST. due signal error DOS-CONT. (I-01):
- DC has been repeatedly switched during
metal feed
- check DC-detection on dosing pipe and
remove fault!
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

PROCESS DISTURBANCES AT WESTOMAT


0502-B.doc

Press F1 = DISTURB. INFO

DISTURB.-35: DOSING CONTACT AFTER END


DIST. due signal error DOS-CONT. (I-01):
- DC has been repeatedly switched after
deaeration
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !

Version: 03.00 A

END
In DOSING ... RUN with electrode DC monitoring,
the disturbance results from the monitoring of the
switch status I-01 = 0, if:

- check furnace-chamber deaeration and


remove fault!
- check log time value of t5-DC (K02)
and modify if necessary !

DIST.
ACKNO.

MODIFY
DATA

05.02

DISTURBANCE 35: DOSING CONTACT AFTER

- remove deposits on dosing pipe!

- check DC-detection on dosing pipe and


remove fault!

3-8

after successful furnace chamber pressure


release (aeration after dosing) and after t5 -DC,
I-01 = from 0 to 1. Evaluate cause and rectify.
Possible causes are:

malfunction of in the furnace chamber


aeration

failure of the solenoid valve of the drive


cylinder

metal feed already carried out.

Acknowledge disturbance.

kg-DOS:
DOSING
NEW

DISTURBANCE 36: DOSING CONTACT AFTER

Press F1 = DISTURB. INFO

DISTURB.-36: DOSING CONTACT AFTER END


DIST. due signal error DOS-CONT. (I-01):
- DC has not been switched after
deaeration

END
In DOSING ... RUN with PneuCo DC monitoring,
the disturbance results from the monitoring of the
switch status I-01 = 0, if:

- remove deposits on dosing pipe !


- check furnace-chamber deaeration and
remove fault!
- check log time value of t5-DC (K02)
and modify if necessary !
- check DC-detection on dosing pipe and
remove fault!
DIST.
ACKNO.

MODIFY
DATA

after successful furnace chamber pressure


release (aeration after dosing) and after t5 -DC,
I-01 = from 1 to 0. Evaluate cause and rectify.
Possible causes are:

failure of PneuCo

metal feed already carried out.

Acknowledge disturbance.

kg-DOS:
DOSING
NEW

DISTURBANCE 37: DOSING OFF

Press F1 = DISTURB. INFO

DISTURB.-37: DOSING OFF

In DOSING ... RUN, the disturbance results from


the monitoring of the switch status I-08 = 1, if:

DISTURBANCE due to DOS-ON (I-08 = 0)


- Turn-on relay DOS-ON (I-08 = 1) has
been switched off
- check turn-on conditions for relay
and remove fault !
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

In DOSING ... RUN, I-08 = from 1 to 0.


Evaluate cause and repair, if necessary.
Possible causes are:

inadvertent activation of the DOS-OFF key

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCES

PROCESS DISTURBANCES AT WESTOMAT


4-8

05.02

0502-B.doc

Version: 03.00 A

DISTURBANCE 38: TOP-STOP

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

Press F1 = DISTURB. INFO

In DOSING ... ON or END with TOP-STOP, the


disturbance results from the monitoring of the
holding pressure, if:

DISTURB.-38: TOP-STOP

- check function of compressed air valv.


and deaering valve,
remove fault !

the measured value of the furnace pressure


chamber does not reach the calculated value for
the TOP-STOP HOLDING PRESSURE. Evaluate
cause and rectify. Possible causes are:

failure of the prop. valve


damaged) or sudden leakage

metal feed not carried out.

Acknowledge disturbance.

(replace

if

DISTURB.- furn. chamb. pressur. too high:

DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 39: TOO MUCH LEAKING


LOSSES
If TOP-STOP PRESSURE HOLDING (or LEVELSCANNING) is activated, the disturbance results
from a discrepancy between the NOMINAL and the
ACTUAL pressure (corresponds to set value of
prop. valve), if:

DISTURB.-39: TOO MUCH LEAKING LOSSES


DIST. of PRESSURE-HOLD in TOP-STOP:
- controller output of prop-valve for
PRESSURE-HOLD is too high:
- leakiness of furnace chamber or
throttling in air feed line

as a consequence of the compensation for the


leakage, the set value for the prop. valve
exceeds 3 V. Rectify cause of leakage at the
furnace body (or the aeration valves)

metal feed not carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

- check furnace chamber for leaks and


remove fault !
- check throttling in air feed line and
remove fault !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 40: TOO MUCH LEAKING


LOSSES
If TOP-STOP is not activated, the disturbance
results from a discrepancy between the NOMINAL
and the ACTUAL pressure increase (corresponds
to set value of prop. valve), if:

as a consequence of the compensation of the


leak loss, the set value for the prop. valve
exceeds 3 V. Rectify cause of leakage at the
furnace body (or the aeration valves)

metal feed already carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DISTURB.-40: TOO MUCH LEAKING LOSSES


DIST. of PRESSURE RISE after DOS-CONT:
- deviation of pressure rise after DC
to RAMP-DOS is too high:
- leakiness of furnace chamber or
throttling in air feed line
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
- check furnace chamber for leaks and
remove fault !
- check throttling in air feed line and
remove fault !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

PROCESS DISTURBANCES AT WESTOMAT


0502-B.doc

Press F1 = DISTURB. INFO

DISTURB.-41: OPERATION LEVEL EMPTY


DIST. of FURNACE OPERAT. FILLING LEVELS:
- minimum operation filling level EMPTY
has been measured at DC

Version: 03.00 A

At furnace filling level monitoring with HPDE, the


disturbance results from the furnace chamber
pressure monitoring at the time of DC, if:

kg-DOS:
DOSING
NEW

furnace chamber has reached switching


threshold for FURNACE EMPTY at the time of
DC, due to continuous emptying of the furnace:

- activ. TOP-STOP and refill furn until


operation fil. level FULL is reached!
MODIFY
DATA

05.02

DISTURBANCE 41: OPERATION LEVEL EMPTY

- check furnace filling level and refil


furnace with approx. 100 kg melt !

DIST.
ACKNO.

5-8

Acknowledge disturbance.

Refill the furnace with approx. 50 to 100 kg


of melt (filling time approx. 15 sec) while
filling level indication is off.

Switch on TOP-STOP (and LEVELSCANNING) activate filling level indication

metal feed already carried out.

Repeat refilling until FURNACE FULL.

DISTURBANCE 42: OVERPRESSURE FURNACE


CHAMBER

Press F1 = DISTURB. INFO

DISTURB.-42: OVERPRESS. FURNACE CHAMBER


DIST. of PRESSURE FURNACE CHAMBER:
- ALLOWED operation pressure of furnace
chamber is exceeded

In DOSING ... RUN, the disturbance results from


the monitoring of the saved limit value for MAX.
DOSING PRESSURE, if:

after DOSING and SOLIDIFICATION:


- OPEN DIE and
- ADVANCE PLUNGER !
- check performance of air valves and
remove fault !
DIST.
ACKNO.

MODIFY
DATA

the furnace chamber pressure exceeds this


limit value. Evaluate cause and rectify. Possible
causes are:

failure of
damaged)

the

prop.

valve

metal feed already carried out.

Acknowledge disturbance.

(replace

if

kg-DOS:
DOSING
NEW

DISTURBANCE 43: FEED PRESSURE TOO HIGH

Press F1 = DISTURB. INFO

DISTURB.-43: FEED PRESSURE TOO HIGH


Allowable feed pressure was exceeded
during dosing operation
- check for losses due to leaks and
check connect. pressure air!
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In DOSING ... RUN, the disturbance results from


the monitoring of the feed pressure, if:

The feed pressure exceeds the calculated limit


value. Evaluate cause and rectify. Possible
causes are:

failure of
damaged)

the

prop.

valve

metal feed already carried out.

Acknowledge disturbance.

(replace

if

DISTURBANCES

PROCESS DISTURBANCES AT WESTOMAT


6-8

05.02

0502-B.doc

Version: 03.00 A

DISTURBANCE 44: FEED PRESSURE TOO LOW

In DOSING ... RUN, the disturbance results from


the monitoring of the feed pressure, if:

The feed pressure does not reach the


calculated limit value. Evaluate cause and
rectify. Possible causes are:

failure of
damaged)

leak losses at the furnace body or the


aeration valves

the

prop.

valve

(replace

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

Press F1 = DISTURB. INFO

DISTURB.-44: FEED PRESSURE TOO LOW


Required feed pressure was not reached
during dosing operation:
- check for losses due to leaks and
check connect. pressure air!
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !

if

DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

lack of pressure in pressure air line

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 45: DC-PRESSURE TOO LOW


In DOSING ... RUN or at the activation of TOPSTOP, the disturbance results from the monitoring
of the furnace chamber pressure at DC, if:

Press F1 = DISTURB. INFO

the measured value for the furnace chamber


pressure is too low. Evaluate cause and rectify.
Possible causes are:

DISTURB.-45: DC-PRESSURE TOO LOW

(incorrectly (too low) positioned scanning


electrode

- check function of compressed air valv.


and DC-detection, remove fault

value entered in LOG K06 for max. melt


level difference is too high

DIST.
ACKNO.

metal feed not carried out.

Acknowledge disturbance.

DISTURBANCE due to low pressure at the


time of DC-dosing contact:

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 46: DC-PRESSURE TOO HIGH


In DOSING ... RUN or at the activation of TOPSTOP, the disturbance results from the monitoring
of the furnace chamber pressure at DC, if:

DISTURB.-46: DC-PRESSURE TOO HIGH

the measured value for the furnace chamber


pressure is too high. Evaluate cause and rectify.
Possible causes are:

blocked feed channel in dosing pipe


value entered in LOG K06 for max. melt
level difference is too high

metal feed already carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DISTURBANCE due to high pressure at the


time of DC-dosing contact:
- check function of compressed air valv.
and DC-detection, remove fault
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

PROCESS DISTURBANCES AT WESTOMAT


0502-B.doc

Press F1 = DISTURB. INFO

DISTURB.-47: DEAERATION FURNACE


Furnace deaering was performed too late
or too slow:
- check deaering valve !
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

Version: 03.00 A

7-8

05.02

DISTURBANCE 47: DEAERATION FURNACE


In DOSING ... RUN and after pressure release
(deaeration), the disturbance results from the
monitoring of the deaeration time (t -DEAE ) during
feed pressure reduction, if:

the measured time/pressure values deviate


from the calculated values. Evaluate cause and
rectify. Possible causes are:

kg-DOS:
DOSING
NEW

deaeration valve opens too late or not


properly

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 48: TOTAL FEED TIME

Press F1 = DISTURB. INFO

DISTURB.-48: TOTAL DOSING TIME


DISTURBANCE - aggregate dosingtime was
too long (t3 + t4):
after DOSING and SOLIDIFICATION:
- OPEN DIE and ADVANCE PLUNGER
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In DOSING ... RUN, the disturbance results from


the monitoring of the dosing counter and the dosing
time, if:

metal feed already carried out.


If the disturbance persists, please contact
StrikoWestofen service department.

DISTURBANCES

PROCESS DISTURBANCES AT WESTOMAT


05.02

8-8

0502-B.doc

blank page

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0503-B.doc

Version: 03.00 A

1-6

PROCESS DISTURBANCES AT DCM

05.03

The logical and repeated closing movement of a DCM


die is signalled to the WESTOMAT control system via
the signal interface.
Prior to each dosing START, the Pro Dos DPC
evaluates the logical switch sequence of these signals.
It also evaluates the switch status of the DCM signals
(die closed or open) during the metal feed.
This ensures that only one dosing process is carried
out for each properly closed DCM die and that such a
process is only completed with closed die.
Prior to pressure START for dosing, non-compliant
switch sequences or status of the DCM signals are
recognised as POSITION ERRORS and the dosing
process is reset so that dosing START is prevented.
After pressure START for dosing, non-conforming
switch sequences of status of DCM signals are
considered as PROCESS DISTURBANCES of the
DCM and result in termination of the dosing and an
error signal.
Acknowledgeable process disturbances are not
prioritized and the first event thus results in a
termination of the process (DISTURBANCE STATUS).
ATTENTION
The inspection of the cause of a disturbance and
any repairs must be carried out only by specifically
trained staff.
Always comply with the safety instructions in the
operating manual.

DISTURBANCE 60: AUTO-OPERATION DCM

Press F1 = DISTURB. INFO

DISTURB.-60: AUTO-OPERATION DCM


DISTURBANCE due to DCM-signal I-18:
- signal has not been switched from 1
to 0 during dosing mode
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In AUTO-DOS RUN, the disturbance results from


the monitoring of the switch status I-18 = 1, if:

in AUTO dosing, I-18 = from 1 to 0. Evaluate


cause and rectify. Possible causes are:

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCES

WESTOMAT P ro Dos DPC


OPERATING MANUAL

PROCESS DISTURBANCES AT DCM


2-6

05.03

0503-B.doc

DISTURBANCE 61: DCM-DIE CLOSES

Version: 03.00 A

DOSING CONTROL

Press F1 = DISTURB. INFO

In AUTO-DOS RUN, the disturbance results from


the monitoring of the switch status I-19 = 1, if:

DISTURB.-61: DCM-DIE CLOSES

after pressure START to DC, and prior to


switching of the signals for DIE CLOSED (I-20 /
21 = from 0 to 1), I-19 = from 1 to 0.

DISTURBANCE due to DCM-signal I-19:

Evaluate causes for the switching I-19 = from 1


to 0. Possible causes are:

metal feed not carried out.

Acknowledge disturbance.

- signal has been switched from 1 to 0


during dosing mode
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 62: DCM-DIE CLOSED 1


In AUTO-DOS RUN, the disturbance results from
the monitoring of the switch status I-20 / 21 = 1, if:

DISTURB.-62: DCM-DIE CLOSED 1

after pressure START to DC, and prior to


switching of the signals for DIE CLOSED (I-22 /
23 = from 0 to 1), I-20 / 21 = from 1 to 0.

DISTURBANCE due to DCM-signal I-20:


- signal has been switched from 1 to 0
during dosing mode

Evaluate causes for the switching I-20 / 21 =


from 1 to 0. Possible causes are:

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 63: DCM-DIE CLOSED 2

Press F1 = DISTURB. INFO

after DOSING and SOLIDIFICATION:


- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In MANUAL or AUTO-DOS mode, the disturbance


results from the monitoring of the simultaneous
switching of the signals I-20 / 21 = from 0 to 1, if:

I-20 = from 0 to 1 and if I-21 = 0 within the


monitoring time of 500 msec

Evaluate cause for switching behaviour I-21.


Possible causes are:

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 64: DCM-DIE READY FOR


INJECTION 1

Press F1 = DISTURB. INFO

DISTURB.-63: DCM-DIE CLOSED 2


DISTURBANCE due to DCM-signal I-21:
- was not switched to 1 during die
shut movement
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In MANUAL mode or AUTO-DOS RUN, the


disturbance results from the monitoring of the
switch status I-22 / 23 = 1, if:

I-22 / 23 = from 1 to 0
Evaluate causes for the switching I-22 / 23 =
from 1 to 0. Possible causes are:

metal feed already carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DISTURB.-64: DCM-DIE READY F. INJECT. 1


DISTURBANCE due to DCM-signal I-22:
- signal has been switched from 1 to 0
during dosing mode
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

PROCESS DISTURBANCES OF DCM


0503-B.doc

Press F1 = DISTURB. INFO

DISTURB.-65: DCM-DIE READY F. INJECT. 2


DISTURBANCE due to DCM-signal I-23:
- signal has not been switched to 1
during closing movement
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

Press F1 = DISTURB. INFO

DISTURB.-66: PLUNGER IN BACK POSIT.


DISTURBANCE due to DCM-signal I-24:
- signal has been switched from 1 to 0
in dosing mode
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

Press F1 = DISTURB. INFO

DISTURB.-67: DCM PLUNGER NOT MOVED

DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

Version: 03.00 A

3-6

05.03

DISTURBANCE 65: DCM-DIE READY FOR


INJECTION 2
In MANUAL or AUTO-DOS mode, the disturbance
results from the monitoring of the simultaneous
switching of the signals I-22 / 23 = from 0 to 1, if:

I-22 = from 0 to 1 and if I-23 = 0 within the


monitoring time of 500 msec

Evaluate cause for switching behaviour I-23.


Possible causes are:

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 66: DCM PLUNGER IN BACK


POSITION
In MANUAL mode or AUTO-DOS RUN, the
disturbance results from the monitoring of the
switch status I-24 = 1, if:

I-24 = from 25.40 mm to 1.


Evaluate causes for the switching I-24 = from 1
to 0.

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 67: DCM PLUNGER NOT MOVED


In AUTO-DOS RUN with electrode DC
monitoring, the disturbance results from the
monitoring of the switch status I-24 = from 1 to 0, if:

approx. 20 sec after RELEASE FOR


INJECTION of I-24 = 1 (I-24 = 0 not switched)

Evaluate causes for the switching I-24 = from 1


to 0.

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCES

WESTOMAT P ro Dos DPC


OPERATING MANUAL

PROCESS DISTURBANCES AT DCM


4-6

05.03

0503-B.doc

DISTURBANCE 68 DC BEFORE DCMDIE CLOSED


In AUTO-SYNCHRON-DOS RUN (and at
synchronization of the operating procedures with
the DCM signal DIE CLOSED), a disturbance is
caused by the monitoring of the switch sequence of
I-01 (DC = start of metal feed) and I-20 / 21 (DIE
CLOSED) - and switching I-01 = from 0 to 1, if I-20
/ I-21 = 0, provided that:

I-20 / I-21 = 0 and I-01 = from 0 to 1 (start of


metal feed into open shot sleeve)

evaluate cause for switching of I-01 = from 0 to


1, if I-20 / 21 = 0. Possible causes are:

in this cycle, switching of I-20 / 21 = from 0


to 1 is delayed

in this cycle, pressure ramp t 2 (to DC) has


been shortened by malfunction of the prop.
valve

metal feed not carried out.

Acknowledge disturbance.

Version: 03.00 A

DOSING CONTROL

Press F1 = DISTURB. INFO

DISTURB.-68: DC BEFORE DCM-DIE CLOSED


DISTURBANCE due to DCM-signal I-20/21:
- DC=DOSING CONTACT switches before
DCM-signals in SYNCHRON. OPERATION
- when repeating, check basic setup
parameters for TOP-STOP and
SYNCHRONIZATION !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCE 69: DC BEFORE


DCM-DIE CLOSED
In AUTO-SYNCHRON-DOS RUN (and at
synchronization of the operating procedures with
the DCM signal DIE CLOSED), a disturbance is
caused by the monitoring of the switch sequence of
I-01 (DC = start of metal feed) and I-22 / 23 (DIE
CLOSED) - and switching I-01 = from 0 to 1, if I-22
/ I-23 = 0, provided that:

I-22 / I-23 = 0 and I-01 = from 0 to 1 (start of


metal feed into open shot sleeve)

evaluate cause for switching of I-01 = from 0 to


1, if I-22 / 23 = 0. Possible causes are:

in this cycle, switching of I-22 / 23 = from 0


to 1 is delayed

in this cycle, pressure ramp t 2 (to DC) has


been shortened by malfunction of the prop.
valve

metal feed not carried out.

Acknowledge disturbance.

Press F1 = DISTURB. INFO

DISTURB.-69: DC BEFORE DCM-DIE CLOSED


DISTURBANCE due to DCM-signal I-22/23:
- DC=DOSING CONTACT switches before
DCM-signals in SYNCHRON. OPERATION
- when repeating, check basic setup
parameter for TOP-STOP and
SYNCHRONIZATION !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

DISTURBANCES

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

PROCESS DISTURBANCES OF DCM


0503-B.doc

Press F1 = DISTURB. INFO

DISTURB.-70: DISCONT. SYNCHRO OPERATION


DISTURBANCE due to DCM-signal I-25:
- after metal feed start (after DC)
signal switches from 0 to 1
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

Version: 03.00 A

5-6

05.03

DISTURBANCE 70: DISCONTINUED


SYNCHRONOUS OPERATION
In AUTO-SYNCHRON-DOS RUN (and at
synchronization of operating processes with the
DCM signal DIE CLOSED) and after the switching
of I-01 = from 0 to 1 (DC = start of metal feed), the
disturbance results from the monitoring of the
switch sequence of I-01 = from 0 to 1 and of I-25
(SYNCHRON. OPERATION DISCONT.), if:

I-22 / I-23 = 0 and if during metal feed (I-01 =


from 0 to 1), switching of I-25 = from 0 to 1 (the
die is to be positioned while the shot sleeve
already contains metal)

Evaluate cause for delayed switching of I-25 =


from 0 to 1 and rectify

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCE 71: DCM-DIE READY FOR

INJECTION 1 = 0
Press F1 = DISTURB. INFO

DISTURB.-71: DCM-DIE READY F. INJECT. 1


= 0

DIST.
ACKNO.

MODIFY
DATA

kg-DOS:
DOSING
NEW

In AUTO-DOS RUN after lapse of program time


t5 -END = RELEASE FOR INJECTION,
the
disturbance results from the monitoring of the
switching of I-22 = from 0 to 1, if:

approx. 15 sec after t5 -END = RELEASE FOR


INJECTION, I-22 = 0 (I-22 = 1 not switched)

Evaluate causes for the switching I-22 = from 1


to 0..

metal feed already carried out.

Acknowledge disturbance.

DISTURBANCES

PROCESS DISTURBANCES AT DCM


05.03

6-6

0503-B.doc

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Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

0600-A.doc

Version: 12.99 A

1-4

GENERAL DESCRIPTION

06.00

ERROR

I-/O

HISTORY

LEVEL

The P ro D os DPC is equipped with HELP


FUNCTIONS that can be activated by means of the
help keys. A help key is available as soon as the LED
of the key is on.

DATA

HELP FUNCTIONS

CYCLE
COUNTER

i/T

DISPLAY

Press key ERROR HISTORY to activate

the following help functions:

/T

PRINT

in this menu, the display shows a list of the


last fifty errors that occurred in DOSING MODE:
- see chapter 06.01

MEMO

Press key

I/O LEVEL

to activate other

help functions:
- see chapter 06.02

To SET DIG-OUT, press key F 5 :

For SIGNALS WO-DCM, press key

this help function is only available in


DOSING MODE or in F5 STATUS:
in this menu, the switch status of the
interface
signals
between
WO
=
WESTOMAT and DCM = die-casting
machine are displayed

in this menu, the switch status of all digital


input and output signals of the P ro D os
DPC control are displayed

For ANALOG IN / OUT, press key F 3 :

F5 :

For DIGITAL IN / OUT, press key F 4 :

this help function is only available in BASIC


STATUS
in this code-locked menu, the switch status
of the digital output signals of the P ro D os
DPC can be changed from 0 = OFF to 1 =
ON and vice versa:

in this menu, the switch status of the analog


input signals of the P ro D os DPC are
displayed

For DATA INIT, press key

This

F2 :

menu is not accessible to the


WESTOMAT operator and is code-locked by
the manufacturer (for internal data test
purposes) !!!

HELP FUNCTIONS

GENERAL DESCRIPTION
2-4

06.00

0600-A.doc

Version: 12.99 A

HELP FUNCTIONS (continued)

Press key

CYCLE COUNTER

to activate

the following help functions:

In this menu, the following status are displayed:

Total cycle counter of dosing operations

Shift cycle counter of dosing operations

Shift cycle counter of disturbances

While the total cycle counter cannot be


modified, the two shift counter can be reset to
zero:
- see chapter 06.03

Press key

DATA DISPLAY

to

activate other help functions:

For CYCLE DATA, press key

In this menu, a table of the process data of


the last five dosing processes is displayed:
- see chapter 06.04

For SETUP DATA, press key

F4 :

F5 :

In this menu, the data of all setup


procedures (entered in the DATA LOG) are
displayed:
- see chapter 06.04

Press key

i/T

to activate

the following help functions:

In this menu, the following


temperatures are displayed:

ACTUAL VALUE of
chamber temperatures

WESTOMAT

melt

and

furnace

melt

and

furnace

NOMINAL VALUE of
chamber temperatures

OVERTEMPERATURE - set
temperature monitoring of melt

value

for

UNDERTEMPERATURE - set
temperature monitoring of melt

value

for

as well as the values of the RUNNING TIME


METER of the WESTOMAT HEATING:

FULL LOAD OPERATION

PARTIAL LOAD OPERATION

- see chapter 06.05

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

GENERAL DESCRIPTION
0600-A.doc

Version: 12.99 A

3-4

06.00

HELP FUNCTIONS (continued)

Press key

i/T

to activate:

In this menu, the temperature values of the


holding temperature operation and the melt
temperature monitoring are entered:

NOMINAL VALUE MELT

UNDERTEMPERATURE MELT

OVERTEMPERATURE MELT

- see chapter 06.06

Press key

PRINT

to

activate other help functions:

To PRINT, press key

F4 :

In this menu, the data output to the


PRINTER interface (output to connected
printer or PC) is selected and activated:
PRINT - history dosing data
PRINT - error history
PRINT - log data
PRINT - regulator configuration
- see chapter 06.07.

For PRINT/MEASURING, press key

F5 :

In this menu, the data output to the


PRINTER interface (output to connected
printer or PC) is selected and activated:
PRINT - cyclic dosing data
PRINT - cyclic quality data
PRINT - cyclic measuring values (only for
process data storage on PC)
- see chapter 06.07.
MEMO FUNCTION
Each data entry must be confirmed with key
ENTER

Subsequently, the LED of the MEMO key is switched to


blinking:

Press key

MEMO

to

permanently store the entry file or the entered


record in the memory for variable data of the
P ro D os DPC.
- see chapter 06.08.

HELP FUNCTIONS

GENERAL DESCRIPTION
06.00

4-4

0600-A.doc

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Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING COTNROL

HELP FUNCTIONS

0601-B.doc

Version: 03.00 B

1-2

ERROR HISTORY

06.01

ERROR

I-/O

HISTORY

LEVEL

Errors, that have occurred in DOSING mode, are


cached by the P ro D os DPC. By activating the help
menu ERROR HISTORY, the respective error list is
displayed.

DATA

A new error event is registered with:

CYCLE
COUNTER

DISPLAY

i/T

/T

PRINT

MEMO

Date

Time and

Error message

and entered in position 1 of the error list. The already


registered error messages are thereby moved back by
one position.
The oldest (approx. fiftieth) error message is thus
deleted from the list.
Dosing operation is not interrupted when the display is
activated.

PROCEDURE
From within any OPERATING MODE of the P ro D os ,
press key

ERROR HISTORY

to activate help menu:


OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
List error history / ESC=back
1 - 02.03.00 - 09:37:41
DISTURB.-06: EMERGENCY STOP DCM
2 - 02.03.00 - 06:12:16
DISTURB.-09: UNDERTEMPERATURE
3 - 01.03.00 - 09:37:41
DISTURB.-06: EMERGENCY STOP DCM
4 - 01.03.00 - 08:24:21
DISTURB.-31: DOSING CONTACT NOT REALIZED
SERVICE ANALOG
DIGITAL
IN
IN / OUT

Display switches to display mode and:

for additional text,

press key

or

to go to next or to previous line

To exit menu press

ESC .

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

ERROR HISTORY
06.01

2-2

0601-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

0602-A.doc

Version: 12.99 A

1-6

I / O (INPUT / OUTPUT) LEVEL

ERROR

I-/O

HISTORY

LEVEL

CYCLE

DATA

06.02

In BASIC STATUS, DOSING MODE or F 5- STATUS of


the P ro D os DPC, press the

help function key

I/O LEVEL

to activate the following help functions:


COUNTER

i/T

DISPLAY

F5 :

- In this menu, the switch status of the interface


signals between the WO = WESTOMAT and the
DCM = die-casting machine are displayed

/T

PRINT

SIGNALS WO-DGM - continue with key

DIGITAL IN / OUT - continue with key

F4 :

- In this menu, the switch status of all digital


INPUTS and OUTPUTS of the P ro D os are
displayed.

MEMO

ANALOG IN / OUT - continue with key

F3 :

- In this menu, the switch status of the analog


signals of the P ro D os DPC are displayed.

DATA INIT - continue with key F 2 :


- can only be activated from basic status
- This menu is not accessible to the WESTOMAT
operator (basic settings = works test data initiated)
and has been equipped by the manufacturer with a
code lock.

To exit menu - press

ESC .

In the BASIC STATUS of the P ro D os , press


help function key

I / O LEVEL

to display SET DIGITAL OUTPUT instead of the


SIGNALS WO-DCM menu.

To SET DIG-OUT, press key

F5 :

- can only be activated from basic status


- In this code-locked menu, the switch status of the
digital output signals of the P ro D os DPC can be
changed from 0 = OFF to 1 = ON and vice versa:
This help function may only be used for a circuit
and function test of the electric parts connected to
the P ro D os DPC.

To exit menu - press

ESC .

HELP FUNCTIONS

I/O(INPUT / OUTPUT) LEVEL


2-6

06.02

0602-A.doc

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

SIGNALS WO-DCM
in this menu, the switch status of the interface
signals between WO = WESTOMAT and DCM =
die-casting machine are displayed.

PROCEDURE
In DOSING MODE or F 5-STATUS of the P ro D os ,
press help function
key

I / O LEVEL:

Display changes to selection mode

Press key F 5 = SIGNALS WO-DCM:

MENU I / O LEVEL
F2 = DATA INIT (StrikoWestofen)
F3 = Displ. of Analog-IN/OUT
F4 = Status display of DIGITAL
INPUTS and OUTPUTS
F5 = Display of SIGNALS between
WESTOMAT and Die-Cast-Machine
DATA
ANALOG
DIGITAL SIGNALS
INIT
IN / OUT IN / OUT WO-DCM

Display changes to display mode:

OFFLINE:
27.65kg
DOS. PIPE: 100/35mm

- = 0 - switch position OFF


- = 1 - switch position ON
- Table of interface signals DCM-WO:
AUTO-FILL TEST ................................
AUTO-OPERATION ON
...........................
DIE CLOSES .............................
DIE CLOSED 1 ...............................
DIE CLOSED 2 ...............................
DIE READY FOR INJECTION 1
.............................
DIE READY FOR INJECTION 2
.............................
PLUNGER IN BACK POSITION
..................................
DISCONT. SYNCHRO OPERATION .
kg-REDUCTION ...........................
kg-INCREASE ...........................

I-17
I-18
I-19
I-20
I-21
I-22
I-23
I-24
I-25
I-26
I-27

- Table of interface signals WO-DCM:


METAL FEED TO AUTO ...............
METAL FEED START ..........................
RELEASE FOR INJECTION 1
............................
RELEASE FOR INJECTION 2
............................
DISTURBANCE METAL SUPPLY
...............
READY FOR DOSING ON
..................................

Press key
to:

O-09
O-10
O-11
O-12
O-13
O-14

F 5 = BACK to confirm and to return

Selection mode
Press ESC to confirm and exit menu.

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
F = MENU / ESC=back

MANUAL
DOSING
CELL IND. ... END

DIE-close
=0 AUTO-operat.
ON =0
DIE-closed 1
=0 AUTO-fill. test
=0
DIE-closed
2 =0 synchr.oper. OFF =0
DIE-ready f.inj.1 =0 kg-decrease
=0
DIE-ready f.inj.2 =0 kg-increase
=0
Plunger back
=1 EMER. STOP DCM
=1
WO on automatic
=0 ready f. dos. ON =1
releas.for inj. 1 =0 metal filling ON =0
relas.for inj. 2
=0 disturb. feed
=0
SERVICE ANALOG
DIGITAL
BACK
IN
IN / OUT

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

I/O (INPUT / OUTPUT) LEVEL


0602-A.doc

Version: 12.99 A

3-6

06.02

DIGITAL IN / OUT
- In this menu, the switch status of all digital
INPUTS and OUTPUTS of the P ro D os are
displayed

PROCEDURE
OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
F = MENU / ESC=back
F2 =
F3 =
F4 =
F5 =

MEN I / O LEVEL
DATA INIT (StrikoWestofen)
Displ. of Analog-IN/OUT
Displ. of DIGITAL
INPUTS and OUTPUTS
Display of SIGNALS between
WESTOMAT and Die-Cast-Machine
DATA
ANALOG
DIGITAL SIGNALS
INIT
IN / OUT IN / OUT WO-DCM

OFFLINE:
27.65kg
DOS. PIPE: 100/35mm
INPUT :
OUTPUT:
No.
I/O
No.
I/O
No.
I/O
No.
I/O

In BASIC STATUS, DOSING MODE or F 5-STATUS of


the P ro D os , press
help function

position
automatic
05 06 07
0/1 1/0 1/0
13 14 15
0/0 0/1 1/0
21 22 23
0/0 0/0 1/0
29 30 31
0/0 0/0 1/0
DIGITAL
IN / OUT

to activate

Display changes to selection mode

Press key

F 4 = DIGITAL IN / OUT:

Display changes to display mode:

MANUAL
DOSING
CELL IND. ... END

Furnace in cast
metal supply in
01 02 03 04
0/0 1/0 1/0 0/0
09 10 11 12
1/0 0/0 0/0 0/0
17 18 19 20
1/1 1/0 0/1 0/0
25 26 27 28
0/1 1/0 0/1 0/0
SERVICE ANALOG
IN

I / O LEVEL

the following help function:

08
1/0
16
1/0
24
1/0
32
1/0

INPUT : = input signal


OUTPUT: = output signal
No.
= input / output number
I/O:
= current switch status:
- 0 = OFF
- 1 = ON

use
to place cursor at No. (input and output):
- below INPUT, the input number
is displayed
- below OUTPUT, the output number
is displayed

BACK

Press key

F 5 = BACK and return to:

Selection mode

Press ESC to confirm and exit menu.

HELP FUNCTIONS

I/O(INPUT / OUTPUT) LEVEL


06.02

4-6

0602-A.doc

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

ANALOG IN / OUT
In this menu, the switch status of the analog
signals of the P ro D os are displayed.

PROCEDURE
In BASIC STATUS, DOSING MODE or F 5-STATUS of
the P ro D os , press
help function key
I / O LEVEL
the following help function:

Display changes to selection mode

Press key F 3 = ANALOG IN / OUT:

to activate

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
F = MENU / ESC=back
MENU I / O LEVEL
F2 = DATA INIT (StrikoWestofen)
F3 = Displ. of Analog-IN/OUT
F4 = Displ. of DIGITAL
INPUTS and OUTPUTS
F5 = Display of SIGNALS between
WESTOMAT and Die-Cast-Machine
DATA
ANALOG
DIGITAL SIGNALS
INIT
IN / OUT IN / OUT WO-DCM

Display switches to display mode - the signal


values of the hardware are displayed:
- **.*** mA
- **** C
- **.*** V

= current amperage
= current converter values for
temperature
= current set value of prop.
valve

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 100/35mm
ESC=back
ANALOG INPUTS AND OUTPUTS
Measuring pressure converter:
6.893
Load cell:
15.695
Thermocouple melt:
698
Thermocouple furnace chamber:
738
Set value prop. valve:
SERVICE ANALOG
IN

mA
mA
C
C

1.452 V
DIGITAL SIGNALS
IN / OUT WO-DCM

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

I/O (INPUT / OUTPUT) LEVEL


0602-A.doc

Version: 12.99 A

5-6

06.02

SET DIG-OUT
This help function is designed for circuit and
function tests of the electric parts connected to the
P ro D os . With this menu, individual DIG-OUT
(digital outputs) can be switched to 1 = ON or 0 =
OFF.
If the INTERNAL TEMPERATURE REGULATOR is
on, the signals I-31 and I-32 (HEATING FULL
LOAD / PARTIAL LOAD) are locked. A respective
message is displayed, if the cursor is placed on
these signals.
If this help function is activated, the
display of the furnace filling level is not
updated.
Therefore,
ensure
that
the
furnace is not refilled.
PROCEDURE
In the BASIC STATUS of the P ro D os , press
***BASIC STATUS***
10.03.00
99:47:12
DOS. PIPE: 100/35mm
F = MENU / ESC=back

CELL IND.

help function key

I / O LEVEL

to activate the following help function:

MENU I / 0 LEVEL
F2 = DATA INIT (StrikoWestofen)
F3 = Displ. of Analog-IN/OUT
F4 = Displ. of DIGITAL
INPUTS and OUTPUTS
F5 = SET DIGITAL OUTPUT
to 0 or 1
DATA
ANALOG
DIGITAL SET DIGINIT
IN / OUT IN / OUT OUT

_Display changes to selection mode

Press key F 5 = SET DIG-OUT:

Display changes to display mode:


- access is code-locked:
- follow instructions

Enter CODE-NO. and press key:

Display changes to display mode:


***BASIC STATUS***
10.03.00 CELL IND.
14:31:17
DOS. PIPE: 100/35mm
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

use

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

- OUTPUT: = output signal


- No.
= input / output number
- OUT:
= current switch status:
- 0 = OFF
- 1 = ON

to place cursor at output

= ENTRY CODE-N and ENTER

press key F 3 to set output


to 1 = ON

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

10.03.00
14:31:17

OUTPUT: Disturbance metal supply


No.
01 02 03 04 05 06
OUT:
0
0
1
0
1
0
No.
09 10 11 12 13 14
OUT:
0
0
0
0
0
1
No.
17 18 19 20 21 22
OUT:
1
1
1
1
1
1
No.
25 26 27 28 29 30
OUT:
1
1
1
1
0
0
RESET
SET
SET
= 1
= 0

HEATING
CELL IND.

to 0 = OFF

07
0
15
0
23
0
31
1

08
0
16
0
24
0
32
0
BACK

press key F 4 to set output

press key F 2 to reset set output


to original switch position

press key F 5 = BACK - to return


to selection mode and to reset set output to
original switch status.

HELP FUNCTIONS

I/O(INPUT / OUTPUT) LEVEL


06.02

6-6

0602-A.doc

blank page

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

0603-B.doc

Version: 03.00 B

1-2

CYCLE COUNTERS

ERROR

I-/O

HISTORY

LEVEL

CYCLE

DATA

COUNTER

DISPLAY

/T

i/T

06.03

The realized dosing processes and all disturbances


occurring in the dosing mode of the P ro D os DPC
are recorded by the cycle counters:

Total cycle counter of dosing operations

Shift cycle counter of dosing operations

Shift cycle counter of disturbances

By means of the CYCLE COUNTER help menu, the


counters are displayed and the shift counters can be
reset to zero, if necessary.
Dosing operation is not interrupted when the display is
called up.

MEMO

PRINT

PROCEDURE
From any OPERATING MODE of the P ro D os ,
press key

CYCLE COUNTER

to activate help menu:


OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
F = MENU / ESC=back
DATE
TIME
1 - TOTAL CYCLE COUNTER
2 - SHIFT CYCLE COUNTER
3 - DISTURB. CYCLE COUNTER

:10.03.00
:11:53:15
:00008178
:0185
:0003
RESET
C. 2+3

Display changes to select mode

in this mode, press

key F 5 = RESET COUNTERS 2+3


the values of the two shift counters are reset
to zero.

If you wish to reset the counters to zero,


continue as follows:
OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
ENTER = RESET COUNTER 2+3 / ESC=back
REALLY RESET COUNTERS
2+3 ?

press key

= ENTER - to delete values

of the shift counters

To exit menu press

ESC .

ATTENTION
By deleting the values of the counters 2 and 3, the
ERROR HISTORY is also deleted.

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

CYCLE COUNTERS
06.03

2-2

0603-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

0604-B.doc

Version: 03.00 B

1-8

DATA DISPLAY

06.04

In this help menu, the following data can be called up:


ERROR

I-/O

HISTORY

LEVEL

CYCLE DATA

- process data of the last five dosing processes

CYCLE

DATA

COUNTER

DISPLAY

SETUP DATA

- saved data of all setup procedures


(content of DATA LOG)
_

i/T

/T

PRINT

MEMO

Dosing operation is not interrupted when this display is


called up. The data of each completed dosing process
are automatically logged and the oldest record is
deleted.

PROCEDURE
From any OPERATING MODE of the P ro D os ,
press key

DATA DISPLAY

to activate help menu:


OFFLINE:
10.65kg
AUTO
DOSING
CELL IND. ... RUN
DOS. PIPE: 80/24 mm
F = MENU / ESC=back
MENU DATA DISPLAY:
F3 - SERVICE phone-numbers
F4 - CYCLE DATA = display of last
five dosing cycles
F5 - SETUP DATA = display of log
data
FILL
INFO
CYLCLE
SETUP
LEVEL
SERVICE DATA
DATA

Display changes to select mode

in this mode:

Press key F 3 = INFO SERVICE - the

telephone numbers of the


STRIKOWESTOFEN service
displayed.

departments

is

Press key F 4 = CYCLE DATA - the

values of the individual dosing processes are


displayed.

Press key F 5 = CYCLE DATA - the

values of the individual setup processes are


displayed.

To exit menu press

ESC .

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA DISPLAY
2-8

06.04

0604-B.doc

Version: 03.00 B

DOSING CONTROL

INFO SERVICE
In selection mode, press key

F3

= INFO SERVICE displays the telephone number of


the StrikoWestofen service departments:

OFFLINE:
10.65kg
AUTO
DOSING
CELL IND. ... END
DOS. PIPE: 80/24 mm
ESC=back
SERVICE-TELEPHONE STRIKOWESTOFEN

Display changes to display mode:

To exit menu press

ESC .

+49(0)6134 = weekdays: 8 to 17 oclock


207883
+49(0)2261
7091140
+49(0)2261 = 24-hours HOTLINE
7091129
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

CYCLE DATA
In selection mode, press key

F4

to display the process data of the last five dosing


processes:

Display changes to display mode:

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

Press key
or

= CYCLE DATA /

= scroll to next

or previous record

To exit menu press

ESC .

DESCRIPTION OF DATA
The data below are only examples
and may not correspond to the actual values:

CYCL = current cycle number

kg
- with
- with
- with

= dosing volume in kg:


- = with dosing volume reduction
+ = with dosing volume increase
= increase and reduction

t1

= Synchronization time in sec only in AUTO-synchron. mode

t2

= time from PRESSURE START to DC

t3

= time from DC to FEED PRESSURE


p-FD reached

t4
= time from FEED PRESSURE p-FD
reached to deaeration

t5

= lag time - from DEAERATION


RELEASE signal to DCM

AUTO
DOSING
CELL IND. ... END

CYCL
kg
t1
t2
t3
t4
t5
t6
t7
t8
t9

ESC=back

22
23
24
25
26
26.00- 10.65 28.25+ 27.75
10.65
0.00
2.01
1.99
1.98
1.97
1.282 1.293 1.305 1.316 1.328
2.676 3.368 3.976 3.452 3.379
0.251 0.241 0.257 0.247 0.239
2.5
2.5
2.5
2.5
2.5
2.8
2.7
2.5
2.8
2.6
2.5
2.0
1.5
2.2
1.9
8.4
4.7
6.0
4.5
4.9
3.8
0.3
0.2
0.5
0.3
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

HELP FUNCTIONS

WESTOMAT ProDos DPC


OPERATING MANUAL

DATA DISPLAY
0604-B.doc

DOSING CONTROL

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

Version: 03.00 B

AUTO
DOSING
CELL IND. ... END

= CYCLE DATA /
CYCL
kg

22
23
26.00- 10.65

24
25
26
28.25+ 27.75
10.65

TdeAE
ac
nc
P-TS
P-DC
P-FD
T-AL
T-OR
kgAL

0.927 0.941 0.919 0.928 0.999


12325 12815 13683 13010 12815
12567 13067 13867 13267 13092
27.58 27.71 27.92 28.17 28.49
37.26 37.58 37.71 37.92 38.17
58.12 58.14 58.12 58.17 58.13
714C 714C 714C 715C 715C
786C 789C 785C 781C 771C
1060/1 1035/1 1010/1 985/1 960/1
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

06.04

Press key
or

ESC=back

3-8

= scroll to next

or previous record

t6

= time from AUTO-closing movement


of DCM
- from DIE CLOSES to DIE CLOSED - only in
AUTO-DOS

t7

= time from AUTO-closing movement of


DCM
- from DIE CLOSED to READY FOR
INJECTION - only in AUTO-DOS

t8

= time from AUTO-INJECTION STOP TIME


of DCM
(DCM stop time for dosing) from READY
FOR INJECTION to RELEASE to DCM - only
in AUTO-DOS

t9

= time from DIE READY FOR INJECTION


to DC - only in AUTO-DOS

t-DEAE = time from ACTUAL counter = NOMINAL


counter to END of metal feed

AT

= ACTUAL counter value of dosing cycle

NT

= NOMINAL counter value (value of dosing


volume to be realized, including -, + or )

P-TS

= measured furnace chamber pressure at


TOP-STOP
HOLD - only if TOP-STOP = ACTIVE

P-DC

= measured furnace chamber pressure at


time of DC

P-FD

= average of the measured furnace chamber


pressure during feed time t4

T-AL

= melt temperature

T-OR

= furnace chamber temperature

kg-AL

= residual volume of melt in furnace


chamber:
- according to CELL indication (e.g. 970/1) or
- according to HPDE indication (e.g. 979/0).

To exit menu press

ESC .

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA DISPLAY
4-8

06.04

0604-B.doc

Version: 03.00 B

DOSING CONTROL

DATA LOG
In selection mode, press key

F5

The saved data (grouped into chapters K01 to K27) of


the individual dosing processes are displayed:

Display changes to display mode:

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm
= DATA LOG

Press key
or

= scroll to next

or previous record

To exit menu press

AUTO
DOSING
CELL IND. ... END
/

ESC=back

DPC-V1.01-05 = software version


10.03.00
= setup date (K01 / K12)
K01. GENERAL DATA:

ESC .

123456
=
111
=
9999
=
1999
=
000000/99 =
85.3.111 =
12.8-0.363=
11.1
mm =
11.1
mm =
10.0 bar =
5.0
bar =
1999
mm =

code-No. technician
WESTOMAT type
product-No
year of production
Serial No. /Year of ProDos-CPU
No. electric plan
pneumatic-plan-No.
diaphragm bypass-valve
diaphragm bypass-valve
oper. press. pr. air supply
setup pressure regulator
launder length

SERVICE-TELEPHONE STRIKOWESTOFEN
+49(0)6134 = weekdays: 8 to 17 oclock
207883
+49(0)2261
7091140
+49(0)2261 = 24-hours HOTLINE
7091129
K02. DOSING CONTACT (DC) WITH:
0
2.5

= (Electrode = 1 / PneuCo = 0)
s = t5-DC (DC after deaeration)

K03. FURNACE FIL. LEVEL DETECTION WITH:


1
= (CELL = 1 / HPDE = 0)
K04. TEMPERATURE REGULATION:
1
= (INTERN = 1 / EXTERN = 0)
1
= (C = 1 / F = 0)
K05. MEASURING PRESSURE CONVERTER (P/I):
0
= nominal operat. press. (Pn)
(200mbar = 0 / 250mbar = 1)
4.00
mA = Zero-point I-signal
20.00 mA = I-signal at Pn-mbar
K06. PRESSURE FURNACE CHAMBER:
40
mbar = MAX-feed pres. (after P-DC)
10
mbar = TOP-STOP-pres. below P-DC
195 mbar = MAX-dosing pres.-DISTURB
240
mm = MAX-bath height difference
25.0
% = furnace chamber-CORRECTION
-20.0
% = counter-CORRECTION
0
% = dosing contact-CORRECTION
K07. PRES. REG. CIRCUIT FURNACE CHAMBER:
10.00
= P1-contents regulator
20.00
= P2-cont. regul. (after DC)
2.00
s = integral action time
K08. SPEED OF PRESSURE RISE:
15.0
= ramp-DC (in mbar/s)
7.5
= ramp-DOSING (in mbar/s)
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

HELP FUNCTIONS

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

DATA DISPLAY
0604-B.doc

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm
= DATA LOG

AUTO
DOSING
CELL IND. ... END
/

ESC=back

Version: 03.00 B

5-8

Press key
or

= scroll to next

or previous record

K09. DOSING PIPE-NO 1:


65
mm =
21
mm =
146
mm =
K10. DOSING
80
24
141

inner diameter
nozzle bore
MIN-ris. h.w/h dos. pipe
PIPE -NO 2:

mm = inner diameter
mm = nozzle bore
mm = MIN-ris. h.w/h dos. pipe

K11. DOSING-SYNCHRONIZATION WITH DCM:


3
0.50

n = after n-AUTO-dosing cycles


s = fill in from DCM-clearing
up to DC (start fill-in)
K12. CODE LOCK FOR SETUP MODE:
******
******

= code No for setup mode S.M.


= code No for OPERATING MODES

K13. DISPLAY MODE (lamps):


10.03.00
= setup date
NO 1 = FURNACE FULL - lamps ON
K14. SWITCHING THRESHOLDS (lamps):
10.03.00 = setup date
23
% = lamp O-21
46
% = lamp O-20
69
% = lamp O-19
92
% = lamp O-18
30
s = lamp O-17 delay
100
% = O-17 lamp FURNACE FULL
K15. FILLING LEVEL SYSTEM with SYSTEM:
= CELL ACTIVE
10.03.00
= setup date
900
kg = fur.operating filling level
400
kg = refill charge
250
kg = 04-REFILL ACKNOWLEDGED
2.000 daN = CELL-nominal load (Qn)
4
mA = Q/I-signal (MIN/no load)
20
mA = Q/I-signal (MAX/at Qn)
K16. CELL-mA-SIGNAL:
10.03.00
4.087
mA
10.883 mA
13.267 mA
13.267 mA

=
=
=
=
=
=

CELL ACTIVE
setup date
Zero point(CELL without load)
at furnace without melt
(MIN) operating level empty
(MAX) operating level full

K17. P/t-MIN - 80/24 = DOS. PIPE NO 1:


10.03.00
= setup date
16.372 mA = CELL at P/t-MIN-MEASURE
31.00 (Vp) = Pres. ramp after DC (mbar/s)
27.58 mbar = P-DC-MIN-pressure
1.973
s = t-DC-MIN-time
21.51 mbar = P-DC/TS-MIN-pressure
1.973
s = t-DC/TS-MIN-time
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

To exit menu press ESC .

06.04

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA DISPLAY
6-8

06.04

0604-B.doc

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

Press key
or

Version: 03.00 B

= scroll to next

or previous record

To exit menu press ESC .

DOSING CONTROL

AUTO
DOSING
CELL IND. ... END

= DATA LOG

ESC=back

K18. P/t-MIN - 80/2 = DOS PIPE NO 2:


10.03.00
= setup date
16.337 mA = CELL at P/t-MIN-MEASURE
27.58 (Vp) = Pres. ramp after DC (mbar/s)
28.78 mbar = P-DC-MIN-pressure
10.845
s = t-DC-MIN-time
27.78 mbar = P-DC/TS-MIN-pressure
1.845
s = t-DC/TS-MIN-time
FILLING LEVEL SYSTEM with HPDE:
= HPDE NOT ACTIVE
10.03.00
= setup date
900
kg = fur.operating filling level
400
kg = refill charge
250
kg = 04-REFILL ACKNOWLEDGED
10
s = Cycle for LEVEL-SCANNING
K20. LANGUAGE / DATE / HOUR
27.03.99

= setup date

K21. REFERENCE-kg-DIAGR. 65/21 mm NO 1:


10.03.00

= setup date

No. kg-DOS. SET-count. ACT-count.


01:
02:
03:
04:
05:
06:
07:
08:
09:
10:

2.35
3.83

1.100
3.200

1.162
3.238

5.21
6.85
7.75
9.48

6.700
8.000
9.100
10.200

6.758
8.092
9.162
10.238

P-FD
20%
50%
75%
95%
M=MAX%
M+0.75s
M+1.25s
M+1.75s
M+2.25s
M+2.75s

K22. OPERATION-kg-DIAGR. 65/21 mm NO 1:


10.03.00

= setup date

No. kg-DOS. SET-count. ACT-count.


01:
02:
03:
04:
05:
06:
07:
08:
09:
10:

2.35
3.83

1.100
3.200

1.162
3.238

5.21
6.85
7.75
9.48

6.700
8.000
9.100
10.200

6.758
8.092
9.162
10.238

FILL
LEVEL

LDH-ON
SETUP

CYLCLE
DATA

P-FD
20%
50%
75%
95%
M=MAX%
M+0.75s
M+1.25s
M+1.75s
M+2.25s
M+2.75s
SETUP
DATA

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

DATA DISPLAY
0604-B.doc

Version: 03.00 B

OFFLINE:
10.65kg
AUTO
DOSING
CELL IND. RUN
DOS. PIPE: 80/24 mm
F = MENU / ESC=back
K23. REFERENCE-kg-DIAGR. 80/24 mm NO 2:
10.03.00

9.70
11.00
13.80
16.17
19.50
23.70
26.00

3.120
4.357
6.730
8.072
10.985
13.120
17.357

3.175
4.383
6.793
8.098
10.065
13.175
17.383

33.25

21.817

22.410

P-FD
20%
50%
75%
95%
M=MAX%
M+0.75s
M+1.25s
M+1.75s
M+2.25s
M+3.00s

K24. OPERATION-kg-DIAGR. 80/24 mm NO 2:


10.03.00

= setup date

No. kg-DOS. SET-count. ACT-count.


01:
02:
03:
04:
05:
06:
07:
08:
09:
10:
K25.

7.50
9.70
11.00
13.80
16.17
19.50
23.70
26.00

2,057
3.120
4.357
6.730
8.072
10.985
13.120
17.357

2.132
3.175
4.383
6.793
8.098
10.065
13.175
17.383

33.25
21.817
22.410
TEMPERATURE REDUCTION (MELT)

10.03.00
SATURDAY
23:30
MONDAY
04:30
- 70 C

=
=
=
=
=
=

P-FD
36%
50%
75%
95%
M=MAX%
M+0.75s
M+1.25s
M+1.75s
M+2.25s
M+3.00s

setup date
start of reduction
time
end of reduction
time
Temperature reduction by

K26. FIRST WARM-UP (COLD START FURNACE):


10.03.00

= setup date

= warm-up in 4h + 20h
700C = end temperature
FILL
LDH-ON
CYLCLE
SETUP
LEVEL
SETUP
DATA
DATA

06.04

Press key
or

= scroll to next

or previous record

To exit menu press

= setup date

No. kg-DOS. SET-count. ACT-count.


01:
02:
03:
04:
05:
06:
07:
08:
09:
10:

7-8

ESC .

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA DISPLAY
8-8

06.04

0604-B.doc

Press key
or

= scroll to next

or previous record

To exit menu press

Version: 03.00 B

DOSING CONTROL

OFFLINE:
10.65kg
AUTO
DOSING
CELL IND. ... RUN
DOS. PIPE: 80/24 mm
F = MENU / ESC=back
K27. REGULATOR CONFIG. (TEMPERATURE)

ESC .

10.03.00
95
=
0
s =
100
s =
6
s =
10
s =
10
s =
5
=
3
=
1
=
1
=
- 2
=
875
=
5
=
temp.
750
=
640
=

= setup date
Xp Proportional range
Tv Rate time
Tn Readjustment time
Tsd - Delay FULL/PARTIAL
Cy1 MIN duration heating OFF
Cy2 MIN duration heating ON
Xshmin Toggling FULL/PARTIAL:
Xshmax Toggling FULL/PARTIAL:
XsdAL1 Hyst. undertemp.
melt
XsdAL2 Hyst. overtemp. melt
Temperature-Offset
AL3 Furnace chamber
XsdAL3 Hyst. furnace chamb.
AL-08-HEATING overtemperature
AL-08-HEATING undertemperature

EMERG.-operation via thermocouple

20
40 =
30 =
5 =
CYLCLE
DATA

= full to part. load


at part. load OFF
OFF to part. load
part. to full load
FILL
LDH-ON
kg-DIA- EINRICHTLEVEL
SETUP
GRAMM
DATEN

HELP FUNCTIONS

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0605-A.doc

Version: 12.99 A

1-2

i / T (INFO / TEMPERATURES)

ERROR

I-/O

HISTORY

LEVEL

CYCLE

06.05

In this help menu, the current operating parameters for


temperatures (melt and furnace chamber) as well as
the cycle counters of the WESTOMAT heating system
are displayed in INFO.

DATA

COUNTER

DISPLAY

i/T

/T

PRINT

MEMO

PROCEDURE
From any OPERATING MODE of the P ro D os ,
Press help key

i/T

to activated INFO display:


OFFLINE:
27.65kg
AUTO
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
ESC=back
TEMPERATURE

MELT

FURN. CHAMBER

ACTUAL
= 694C
= 723C
NOMINAL
= 695C
OVERTEMPERATURE =
15C
= 875C
UNDERTEMPERATURE =
10C
COUNTER HEATING
FULL LOAD OPERATION
=
126:34/h
PARTIAL LOAD OPERATION
= 10942:43/h
MEMORY
= JA

MEMORY
= NEIN

ZURCK
EINGABE

Display changes to display mode:

To exit menu - press

ESC .

HELP FUNCTIONS

i / T (INFO / TEMPERATURES)
06.05

2-2

0605-A.doc

blank page

Version: 12.99 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

0606-A.doc

Version: 12.99 A

1-2

/ T (INPUT TEMPERATURE VALUES)

ERROR

I-/O

HISTORY

LEVEL

From any OPERATING MODE of the P ro D os ,


Press help key

CYCLE
COUNTER

i/T

PRINT

DATA

06.06

/T

To activate the input menu for the parameters of the


melt holding temperature:

DISPLAY

* * * NOMINAL VALUE - for the holing temperature


of the melt

- * * NOMINAL VALUE - for the monitoring of the


permitted undertemperature of
the melt

+ * * NOMINAL VALUE - for the monitoring of the


permitted overtemperature of the
melt

/T

MEMO

PROCEDURE
From any OPERATING MODE of the P ro D os ,

Press help key

/T

to activate the input menu for the parameters of the


melt holding temperature:
OFFLINE:
27.65kg
AUTO
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
, INPUT, ENTER and MEMO / ESC=back
TEMPERATURE MELT

Display changes to entry status:


the current operating data is displayed:
- the operator has the option to modify one or
several values

695C = NOMINAL VALUE MELT


-

15 = UNDERTEMPERATURE MELT
10 = OVERTEMPERATURE MELT
DIGITAL
INFO SERVICE ANALOG
IN
IN / OUT

For operating instructions - press INFO

To exit menu - press ESC.

Use

keys to place cursor

at the line of the parameter

enter new temperature value

and confirm entry with


the LED of the MEMO key is blinking
- continue with further entries or save:

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

/ T (INPUT TEMPERATURE VALUES)


06.06

2-2

entry - press key

0606-A.doc

MEMO

Version: 12.99 A

DOSING CONTROL

to save entry, and:

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
ATTENTION: DATA HAVE BEEN MODIFIED!

F1

(MEMORY=YES) = save

F1 - SAVE DATA MODIFICATION

and back to initial status

F2 - DO NOT SAVE DATA MODIFICATION AND


KEEP DATA UNMODIFIED

F 3 MEMORY=NO - return to previous values


and back to initial status

F5

BACK - return to entry form,


entered data is not saved and the display
returns to the entry form for further
modifications.

F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

The modification of the parameters for the melt holding


temperature is now completed and the new NOMINAL
value is displayed.

X = current VALUE of melt temperature


at the activated operating mode EMERGENCY
HEATING,
this display is blinking and the indicated value
does not correspond with the melt temperature

W = NOMINAL VALUE of melt temperature.

694
W

695

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTOL

HELP FUNCTIONS

0607-B.doc

Version: 03.00 B

1-6

PRINTER

06.07

ERROR

I-/O

HISTORY

LEVEL

CYCLE
COUNTER

DATA
DISPLAY

i/T

/T

PRINT

MEMO

In this menu, the data output to the PRINTER interface


(output to connected printer or PC / terminal or hyperterminal) is selected and activated: The data output
can be completed in two different ways:
- INDIVIDUAL PRINTER OUTPUT or
- CYCLICAL / CONTINUOUS output:

The INDIVIDUAL PRINTER OUTPUT is mainly


selected for the subsequent recording of saved
data, e.g.:

DOSING DATA - HISTORY


- Process data of the last five dosing cycles

ERROR - HISTORY
- Date, time and text of the last fifty ERROR
events

LOG DATA
- Data of all setup procedures

REGULATOR CONFIGURATION
- only with activated internal regulator
- Configuration data of the internal temperature
regulator (also recorded in LOG DATA) and
data regarding warming-up, temperature
reduction and the melt temperature holding
operation

After output, this output mode is automatically


terminated.

The CYCLICAL / CONTINUOUS output provides


records of serial process data from the current
dosing operation:

CYCLIC DOSING DATA


- complete process data including QUALITY
DATA

CYCLIC QUALITY DATA


- only quality-relevant process data including
date and time

ANALOG MEASURED VALUES


- not available for printer - output only to PC
- Analog values of the proportional valve, the
furnace
chamber
measuring
pressure
converter and the time of dosing contact

Dosing operation is not interrupted during data


output. After completion of the output, the output
mode must be reset.
TRANSFER PARAMETERS
Interface
: RS 232 (24V / series)
Bauds 9600
Parity
: None
Data bits
:8
Stop bit
:1
Handshaking: FLAG and XON / XOFF.

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

PRINTER
2-6

06.07

0607-B.doc

Version: 03.00 B

DOSING CONTROL

PROCEDURE
From any OPERATING MODE of the P ro D os ,
press key

PRINT

to activate help menu:

Display changes to selection mode for individual or


cyclical data output:

OFFLINE:
10.65kg
AUTO
DOSING
CELL IND. ... END
DOS. PIPE: 80/24 mm
F = MENU / ESC=back
F4 - individ. printer output
F5 - cyclical printer output
- cyclical measuring data output
FILL
LEVEL

For INDIVIDUAL OUTPUT, press key

F4

= PRINT:

The unit changes to selection mode for this


output option:

F1

F2

LDH-ON
SETUP

PRINT

F3

F4

Set cursor to desired line

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

and press key

1. PRINT - history dosing data

PRINT
MEASURING

F5

AUTO
DOSING
CELL IND. ... END

= SELECTION AND ENTER / ESC=back


= ENTER

- the data is transferred and the display


returns to selection mode

To exit menu press ESC .

2. PRINT - error history


3. PRINT - log data
4. PRINT - regulator configuration
FILL
LDH-ON
PRINT
PRINT
LEVEL
SETUP
MEASURING

For CYCLICAL / CONTINUOUS output


press key F 5 =
and select PRINT/MEASURING

The unit changes to selection mode for this


output option:

Set cursor to desired line


and press key
-

= ENTER

the output mode changes from


PASSIVE to ACTIVE and the data is
transferred.

To exit menu press

ESC .

To complete output, again select CYCLICAL


OUTPUT and set output mode back from
ACTIVE to PASSIVE.

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

AUTO
DOSING
CELL IND. ... END

= SELECTION AND ENTER / ESC=back


passive:

cyclic dosing data

passive:

cyclic quality data

passive: cyclic measuring values


FILL
LDH-ON
PRINT
PRINT
LEVEL
SETUP
MEASURING

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

PRINTER
0607-B.doc

Version: 03.00 B

3-6

06.07

EXAMPLES - INDIVIDUAL OUTPUTS


Record of last
CYCL
001222
h
09:36
T-act 701C
ac
21318
tCYCL 999.9
t1
1.91
t3
2.076
t5
2.0
t7
2.5
t9
0.5
P-TS
27.58
P-FDm 68.12
... and records of the
dosing processes

dosing process:
kg
27.65
DMY
12.07.99
T-nom 700C
nc
20738
ALU
1070/1
t2
1.25
t4
3.251
t6
2.8
t8
6.4
tDEAE 0.62
P-DC
37.26
T-OR
786C
four previous.

27.02.00
14:37
DISTURB.-05: EMERGENCY STOP WESTOMAT
27.02.00
DISTURB.-09: UNDERTEMPERATURE

- In this mode, the dosing data of the last five


dosing processes are transferred to the PRINTER
interface.
- The data transfer is automatically terminated after
completion.

PRINT - error history


- In this mode, the data of the last fifty disturbances
that have occurred in dosing mode are
transferred to the PRINTER interface

08:25

- The data transfer is automatically terminated after


completion.

02.03.00
10:42
DISTURB.-41: OPERATION LEVEL EMPTY

K25. TEMPERATURE-REDUCTION (MELT)


03.03.00 = setup date
FRIDAY
= start of reduction
23:30
= time
MONDAY
= end of reduction
03:45
= time
- 70
= temperature reduction value
K26. FIRST WARM-UP (COLD START FURNACE):
03.03.00
= setup date
= warm-up in 4h + 20h
690
= end temperature
K27. REGULATOR CONFIGUR.(TEMPERATURE)
03.03.00
= setup date
95
= Xp Proportional range
0
s = Tv Rate time
100
s = Tn Readjustment time
6
s = Tsd - Delay FULL/PARTIAL
10
s = Cy1 MIN duration heating OFF
10
s = Cy2 MIN duration heating ON
3
= Xshmin Toggling FULL/PARTIAL:
5
= Xshmin Toggling FULL/PARTIAL:
1
= XsdAL1 Hyst. undertemp.
melt
1
= XsdAL2 Hyst. overtemp. melt
0
= Temperature-Offset
875
= AL3 Furnace chamber
5
= XsdAL3 Hyst.furnace chamb. temp.
750
= AL-08-HEATING overtemperature
640
= AL-08-HEATING undertemperature
EMERG.-operation via thermocouple
20
= full to part. load
40
= at part. load OFF
30
= OFF to part. load
5
= part. to full load
MELT TEMPERATURE
695 C = NOMINAL VALUE MELT
-10 C = UNDERTEMPERATURE MELT
+15 C = OVERTEMPERATURE MELT

PRINT - history dosing data

PRINT - regulator configuration


- In this mode, and provided that the internal
regulation is activated, the data of the regulator
configuration, the warm-up operation, the
temperature reduction and the melt temperature
holding operation is transferred to the PRINTER
interface.
- The data transfer is automatically terminated after
completion.

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

PRINTER
06.07

4-6

0607-B.doc

Version: 03.00 B

DOSING CONTROL

EXAMPLES - INDIVIDUAL OUTPUTS (continued)

PRINT - log data


- In this mode, the complete log is transferred to
the PRINTER interface.

... This display corresponds with that shown in


chapter 06.04:
- The protocol chapters K01 to K24 or to K27
are displayed.

ATTENTION
If the internal (temperature) regulator is not
activated, the protocol data of chapter K25 to K27
are not available.
The data transfer is automatically terminated after
completion.

Sofware version
Setup data of log (K01 to K12)
K01. GENERAL DATA
K02. DOSING CONTACT (DC) WITH:
Electrode or PneuCo
K03. FURNACE FIL. LEVEL DETECTION WITH:
CELL or HPDE
K04. TEMPERATURE REGULATION:
INTERNAL or EXTERNAL
K05.
K06.
K07.
K08.
K09.
K10.
K11.
K12.

MEASURING PRESSURE CONVERTER (P/I)


PRESSURE FURNACE CHAMBER:
PRES. REG. CIRCUIT FURNACE CHAMBER
SPEED OF PRESSURE RISE
DOSING PIPE NO 1
DOSING PIPE NO 2
DOSING-SYNCHRONIZATION WITH DCM
CODE LOCK FOR SETUP MODE

K13.
K14.
K15.
K16.
K17.
K18.
K19.
K20.
K21.
K22.
K23.
K24.
K25.
K26.
K27.

DISPLAY MODE (lamps)


SWITCHING THRESHOLDS (lamps)
FILLING-LEVEL SYSTEM with CELL
CELL-mA-SIGNAL
P/t-MIN - DOSING PIPE NO 1
P/t-MIN - DOSING PIPE NO 2
FILLING-LEVEL SYSTEM with HPDE
LANGUAGE / DATE / HOUR
REFERENCE-kg-DIAGRAM NO 1
OPERATION-kg-DIAGRAM NO 1
REFERENCE-kg-DIAGRAM NO 2
OPERATION-kg-DIAGRAM NO 2
TEMPERATURE REDUCTION (MELT)
FIRST WARM-UP (COLD START FURNACE)
REGULATOR CONFIGUR. (TEMPERATURE)
EMERGENCY HEATING

EXAMPLES:
CYCLICAL / CONTINUOUS

CYCLIC DOSING DATA


- In this mode, a data record of each individual
dosing process is transferred to the PRINTER
interface after the process is completed. The data
is the same as for that for HISTORY DOSING
DATA.
- The transfer is carried out until the data output is
manually terminated.

CYCL
h
T-act
ac
tCYCL
t1
t3
t5
t7
t9
P-TS
P-FDm

001222
09:36
701C
21318
999.9
1.91
2.076
2.0
2.5
0.5
27.58
68.12

kg
DMY
T-nom
nc
ALU
t2
t4
t6
t8
tDEAE
P-DC
T-OR

27.65
12.07.99
700C
20738
1070/1
1.25
3.251
2.8
6.4
0.62
37.26
786C

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

HELP FUNCTIONS

PRINTER
0607-B.doc

Version: 03.00 B

5-6

06.07

EXAMPLES:
CYCLICAL / CONTINUOUS (continued)

CYCL
h
T-act
ac
Tcycl

1222
09:36
701C
22318
119.9

kg
DMY
T-nom
nc
ALU

26.00
12.07.99
700C
21270
1070/1

CYCLIC QUALITY DATA


- In this mode, the QUALITY DOSING record of
each individual dosing process is transferred to
the PRINTER interface.
- The transfer is carried out until the data output is
manually terminated.

DATA

CYCL 001222: cycle counter, cannot be modified


kg

=27.65 : realized dosing volume


- with - after kg value = of volume
reduction
- with + after kg value = of volume
increase
- with +/- after kg value = with
simultaneous dosing volume
increase and reduction

= 09:36 : Cycle time (hours : minutes)

DMY 12.07.99 : Cycle date (D / M / Y)


T-ACT =701C : Actual value of melt temperature (in
C/F)
- if external REGULATOR =
ACTIVE, value 0 C

T-NOM =700C :Nominal value of melt temperature (in


C/F)
- if external REGULATOR =
ACTIVE, value 0 C

ac

=21318 : Actual counter according to process


monitoring
in dosing cycle

nc =21000 : Nominal counter according to realized


dosing
volume

tCYCL = 119.9 : Measured time of total AUTO


production cycle of cast
- in MANUAL-DOS = 0

ALU =1070/1 : available remaining melt volume


in the furnace
- with /1 = acc. to CELL filling level
indication
- with /0 = acc. to HPDE filling level
indication

CYCLICAL MEASURING DATA (analog values)


- not available for printer - output only to PC
- In this mode, analog data from the proportional
valve, the furnace chamber measuring pressure
converter and the time of dosing contact is
transferred to the PRINTER interface.
- The transfer is carried out until the data output is
manually terminated.

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

PRINTER
06.07

6-6

0607-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

HELP FUNCTIONS

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

0608-A.doc

Version: 12.99 A

1-2

MEMO (SAVE)

ERROR

I-/O

HISTORY

LEVEL

CYCLE

DATA

COUNTER

DISPLAY

i/T

/T

PRINT

MEMO

06.08

At commissioning of the unit, the setup procedures are


completed for the operating functions of the P ro D os
DPC, including the input of specific data for the control
operations. This data and parameters can be modified
as often as necessary and are saved in a memory that
is equipped with a buffer battery so that the data are
not affected by power failures, etc.
The help function key MEMO is used to save such
information. Commands for saving must be confirmed
each time with the ENTER key. If data is not to be
saved, the procedure can by aborted and the
previously entered values apply.

PROCEDURE
12.07.99
HEATING
DOS. PIPE: 80/24mm
CELL IND.
16:38:12
OFFLINE: kg-DOS-NEW
INPUT, ENTER and MEMO / ESC=back
kg-DOS-RANGE:

6.50 to 15.0 kg

8.55 kg = dosing volume (OFFLINE)


+ 0.00 kg = AUTO-increase up to 1.75
-0.95 kg = AUTO-decrease up to 0.95
34
% = furnace chamber-CORRECTION
1.80 s = t5 - lag time
P-FD = 80 mbar / t4 = 1.97 s
SERVICE ANALOG
DIGITAL
IN
IN / OUT

Each data entry must be confirmed with key


ENTER

Subsequently, the LED of the MEMO key is switched to


blinking:

Press key

MEMO

to

change to the entry form. In this operating mode,

OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... END
DOS. PIPE: 100/35mm
ATTENTION: DATA HAVE BEEN MODIFIED!

F1

F1 - SAVE DATA MODIFICATION


F2 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

MEMORY = YES

Saving can be aborted by pressing key F3. The


newly entered values are not saved and the
previous values apply unmodified:

F3

F5 - BACK TO ENTRY
MEMORY
= YES

press key F1 to overwrite previous values and


save newly entered values.

MEMORY = NO

The saving procedure can be reset by means of


key F5. The display changes back to the entry
form, where the newly entered values are
shown, while the previous values are still saved:

F5

BACK TO ENTRY

HELP FUNCTIONS

WESTOMAT P ro Dos DPC


OPERATING MANUAL

MEMO (SAVE)
06.08

2-2

0608-A.doc

blank page

Version: 12.99 A

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

0700-B.doc

Version: 03.00 B

1-4

GENERAL INSTRUCTIONS

07.00

When supplied, all new Pro Dos DPC control


systems are set up with internal test data. This data is
however not suitable for productive operation of the
WESTOMAT.
At commissioning of the WESTOMAT unit, the
specific data for the furnace and the variable operation
parameters must be entered in SETUP mode. After
this is completed, the Pro Dos DPC is ready for
operation.
This data is saved in a permanent memory, which is
protected against data loss (e.g. at power failure) by a
buffer battery. The data can at any stage be modified.
NOTE (regarding setup mode):

THE SETUP PROCEDURE AS DESCRIBED IN


THIS CHAPTER MAY ONLY BE COMPLETED BY
SPECIALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
THE
INSTRUCTIONS IN THIS MANUAL.

SAFETY

SETUP MODE - STRUCTURE


The setup mode is divided into several menu-driven
setup programmes:

LDT SETUP (F 3) - Setup programme for the


selection of the programme language, entry of date
and time:
see chapter 07.01

LOG DATA (F 1) - Setup programme for the entry


of furnace-specific data and operating parameters:
see chapter 07.02

REGULATOR HEATING (F 5 ) - Setup programme


for the configuration of the regulator, temperature
reduction and warm-up operations:
see chapter 07.03

FILLING INDICATION (F 2) - Setup programme for


the entry of filling level data, selection of scanning
mode and switching thresholds of display lamps,
setup of filling level scanning and max. rate of
pressure increase in the furnace chamber:
see chapters 07.04, and
for operation with load cell (CELL) - chapter
07.04.3
for operation with pneumatic pressure
detection system (HPDE) chapter 07.04.4

kg-DIAGRAM (F 4) - Setup programme for the entry


of Reference Dosing Volumes (RDV) and data input
for operation-kg diagrams:
see chapter 07.05.

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

GENERAL INSTRUCTIONS
07.00

2-4

0700-B.doc

Version: 03.00 B

DOSING CONTROL

SETUP PROCEDURE
After switching on of the completely installed Pro Dos
DPC, the BASIC STATUS is shown in the display:

The following display data regarding:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 80/24mm
EXT-KEY DOS-ON or F5 = DOSING

Dosing pipe size


Current date
Current time
Installed software version
Setup date
Melt available in furnace in kg

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


P r o D o s

is only an example and may deviate from the actual


values.

DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO
... Multi-function keys

F1

to

F5

F1
After deletion of all setup data or after modification of
the data structure, (e.g. after the loading of a new,
incompatible software version), the display changes to
the selection status for the general SETUP MODE:

The instruction line contains information on how to


complete the above setup procedures in the given
sequence.

... Start with LDT SETUP by pressing

multi-function key

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F3 .

F2

F3

F4

F5

SETUP MODE:

10.03.00
13:34:57
F3 = LDT-SETUP / ESC=back

SETUP of OPERATING DATA for:


F1: LOG DATA .....................
F2: FILLING INDICATION (SCAN).....
F3: LDT = language /date/time ....
F4: kg-DIAGRAM ...................
F5: REGULATOR DATA and HEAT-FUNCT.
LOG.
-DATA

F1

=
=
=
=
=

0
0
0
0
0

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

To modify setup data, press

***BASIC STATUS***
DOS. PIPE 80/24mm
EXT-KEY DOS-ON

or

10.03.00
13:34:57
F5

HEATING
SCAN=CELL
.

DOSING

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

multi-function key F 2 = SETUP in BASIC


STATUS.

P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE:

SETUP MODE

GENERAL INSTRUCTIONS
0700-B.doc

Version: 03.00 B

10.03.00
13:34
F = MENU / ESC=back

F1

=
=
=
=
=

F3

F4

The display changes to selection mode of the


general SETUP MODE:
values of the individual setup option:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

07.00

The visualisation field shows the currently saved

SETUP of OPERATING DATA for:


F1: LOG DATA .....................
F2: FILLING INDICATION (SCAN).....
F3: LDT = language /date/time ....
F4: kg-DIAGRAM ...................
F5: REGULATOR DATA and HEAT-FUNCT.
LOG
DATA

3-4

Activate required SETUP OPTION:

by pressing the associated multi-function key


(F1 to F5):

- The display changes to the entry form with


instructions (with or without code lock).

F5

- The multi-function keys are


assigned to
specific operations as described in the
display fields.
The access to the setup mode can be locked by a
code. The code lock (freely selectable CODE
number) prevents unauthorised manipulations in
the BASIC SETTINGS of the Pro Dos DPC and is
entered and saved in the log (K 12).
If the SETUP MODE is code-locked,

= ENTRY CODE-N and ENTER

Enter code number and press


The SETUP MODE is now accessible. The
display changes to the ENTRY FORM.

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

F x is pressed,

the respective form (e.g. after F1 = LOG DATA)


is displayed, with instruction to enter code
number.

10.03.00
SETUP MODE:
13:34:57
LOG DATA
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

and the multi-function key

If the SETUP MODE is not code-locked,

and the multi-function key

F x is pressed ,

the respective form (e.g. after F1 = LOG DATA)


is displayed.
10.03.00
SETUP MODE:
13:34:57
LOG DATA.
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

After pressing key


the SETUP MODE is accessible. The display
changes to the ENTRY FORM.

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

GENERAL INSTRUCTIONS
0700-B.doc

4-4

07.00

Version: 03.00 B

DOSING CONTROL

INSTRUCTIONS: DATA ENTRY AND SAVING:


The data is entered by means of the front panel
keyboard, following the instructions on the display
(particularly those in the instruction line). The following
general commands apply:

Press

Entry: e.g.

or

to move cursor to desired line

...

, press key

, and

the LED of the MEMO key is blinking (ready to


save):

proceed with the next entry.

To save data - press key

F1

MEMORY = YES:

The new values are saved

F3

MEMO and:

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

10.03.00
SETUP MODE:
13:34:54
??
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

MEMORY
= NO

BACK TO
ENTRY

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

ATTENTION
To exit setup procedure:

press key
ESC - display returns to
previous status

press key
STATUS

If data has been modified prior to pressing

ESC - display returns to BASIC

ESC,
you are prompted to save or discard the
modifications:
- MEMORY = YES
- MEMORY = NO
- BACK TO ENTRY

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

0701-B.doc

Version: 03.00 B

1-6

LDT: LANGUAGE / DATE / TIME

07.01

In the LDT-SETUP, the following operational functions


of the WESTOMAT Pro Dos DPC control are set up:

LANGUAGE - Selection of one of the available


languages of the software for operation

DATE - Entry of current date

TIME - Entry of current time.

The setup date of the LDT-SETUP is automatically


entered in the LOG (K 20.).

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

SETUP MODE:

F3

F4

F5

F1

F4

The display changes to selection mode of the


general SETUP MODE:

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F3

F 2 = SETUP

The visualisation field shows the currently saved

10.03.00
13:34
F = MENU / ESC=back

F2

multi-function key

values of the individual setup option:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

SETUP of OPERATING DATA for:


F1: LOG DATA .....................
F2: FILLING INDICATION (SCAN).....
F3: LDT = language /date/time ....
F4: kg-DIAGRAM ...................
F5: REGULATOR DATA and HEAT-FUNCT.
LOG
DATA

F5

Select - LDT-SETUP by pressing

multi-function key

F3 .

SETUP MODE

LDT: LANGUAGE / DATE / TIME


2-6

07.01

0701-B.doc

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

ATTENTION:

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).

If the SETUP MODE is code-locked,

press multi-function key F 3


The display form with instructions for entry of
the code number appears

Enter code number and press


to access SETUP OPTIONS for:

LANGUAGE - select

DATE - enter

TIME - enter

10.03.00
SETUP MODE:
13:34:57
LANGUAGE/DATE/TIME
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key F 3


The display form with instructions appears.

10.03.00
SETUP MODE:
13:34:57
LANGUAGE/DATE/TIME
ATTENTION: OPER. INSTRUC. / ESC = back

Press key
to access SETUP OPTIONS for:

Select LANGUAGE

Set DATE

Set TIME

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


OPERATING MANUAL

SETUP MODE

LDT: LANGUAGE / DATE / TIME


0701-B.doc

DOSING CONTROL

Version: 03.00 B

3-6

07.01

SELECT LANGUAGE

10.03.00
SETUP MODE:
13:34
LANGUAGE/DATE/TIME
F = MENU / ESC=back

After entry of code number, continue by pressing

K20. LANGUAGE / DATE / TIME


F3 = set time
F4 = set date
F5 = select language

F1

F2

TIME

DATE

F3

F4

LANGUAGE

multi-function key
displayed:

F5

10.03.00
SETUP MODE:
13:34
LANGUAGE
SELECTION AND ENTER / ESC=back
SELECT LANGUAGE
Language

F 5 - the following form is

Select LANGUAGE by pressing:


or

and the available languages are

displayed alternatively

Select displayed language by pressing

English

All texts are now displayed in the selected


language.

Press key
status

ESC - display returns to initial

press key
STATUS

ESC - display returns to BASIC

The LANGUAGE setup is now completed.

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LDT: LANGUAGE / DATE / TIME


4-6

07.01

0701-B.doc

Version: 03.00 B

DOSING CONTROL

SET TIME
ATTENTION
The current date is used for processing and quality
data regarding the dosing processes, for error
events, the saving of setup data and the operation
of weekend temperature reductions.
After entry of code number, continue by pressing:
10.03.00
SETUP MODE:
13:34
LANGUAGE/DATE/TIME
F = MENU / ESC=back
K20. LANGUAGE / DATE / TIME
F3 = set time
F4 = set date
F5 = select language

multi-function key
displayed:

F 4 - the following form is

F1

to enter DATE:
current date
- is the previously entered date
new date
is the date to apply from now on

to

F3

F4

SET DATE

to enter NEW date - day,

month, year (ddmmyy). The cursor stops at the


last digit of the year.
Confirm NEW DATE by pressing key

DATE

The NEW DATE is now saved.

Press key
status

ESC - display returns to initial

press key
STATUS

ESC - display returns to BASIC

The setup procedure for DATE is completed.

LANGUAGE

F5

10.03.00
SETUP MODE:
13:34
DATE
ENTER day, month, year / ESC=back

press key

F2

TIME

current date
new date

10.03.00
10.03.00

SETUP MODE

WESTOMAT ProDos DPC


OPERATING MANUAL

LDT: LANGUAGE / DATE / TIME


0701-B.doc

DOSING CONTROL

Version: 03.00 B

5-6

07.01

SET TIME
ATTENTION
The current time is used for processing and quality
data regarding the dosing processes, for error
events, the saving of setup data and the operation
of weekend temperature reductions
After entry of code number, continue by pressing:
10.03.00
SETUP MODE:
13:34
LANGUAGE/DATE/TIME
F = MENU / ESC=back
K20. LANGUAGE / DATE / TIME
F3 = set time
F4 = set date
F5 = select language

F1

F2

TIME

DATE

F3

F4

LANGUAGE

multi-function key
displayed:

F5

to enter TIME:
current time
- is the previously entered time
new time
is the time to apply from now on

press key

10.03.00
SETUP MODE:
13:34:57
TIME
ENTER h, min, sec / ESC=back
SET TIME
current time
new time

F 3 - the following form is

0 to 9
to enter new time as hour,
minutes, seconds (hh:mm:ss)

13:34:57
13:34:57

The cursor stops at the last digit of the seconds.

Confirm NEW TIME by pressing key

the NEW TIME is now saved.

The setup procedure for TIME is completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

SETUP MODE

LDT: LANGUAGE / DATE / TIME


07.01

6-6

0701-B.doc

blank page

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

0702-B.doc

Version: 03.00 B

1 - 14

LOG DATA

07.02

The individual data and operating parameters (of all


setup procedures) are entered in the LOG grouped in
chapters K 01 to K 27 and labelled with the respective
setup date.
In setup mode, the following
entered:

LOG DATA must be

GENERAL DATA -in K 01 and

OPERATING PARAMETERS - in chapters K 02 to K


12, defining the basic settings of the WESTOMAT
Pro Dos DPC system.

The setup date of the LOG is automatically entered in


K 01.
From K 13, the chapters display data from other setup
procedures. This data can only be read but not
modified.

GENERAL DATA for:

K 01 - Input of general data

OPERATING PARAMETERS for:


K 02 - Detection of dosing contact with:

ELECTRODE OR PneuCo

K 03 - Furnace filling level detection with:


a load cell (CELL) or
a hydraulic-pneumatic pressure detection
SYSTEM (HPDE)

K 04 - Temperature regulation with:


an INTERNAL regulator and temperature in
C or F
an EXTERNAL regulator

K 05 - Furnace chamber measuring pressure


converter:
Measuring range and signals

K 06 - Pressure in furnace chamber:


max. dosing pressure
TOP-STOP holding pressure
max. furnace pressure
Correction values for:
Furnace chamber CORRECTION
Counter CORRECTION
Dosing contact CORRECTION

K 07 - Furnace chamber regulator circuit:


Parameters of pressure regulator
characteristic

K 08 - Rate of pressure rise:


Ramp R-DC for pressure increase from
pressure-free furnace chamber to dosing
contact (DC)
Ramp R-DC/TS for pressure increase from
TOP-STOP to dosing contact (DC)

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
07.02

2 - 14

0702-B.doc

K 09 - Dosing pipe No. 1:


Internal diameter and nozzle bore
Min. rising height of melt in dosing pipe

K 10 - Dosing pipe No. 2:


Internal diameter and nozzle bore
Min. rising height of melt in dosing pipe

K 11 - Process synchronization with DCM:


after n-AUTO dosing cycles
Min. time lag between DCM signal for
release for injection and the DC = feed
start

K 12 - Code lock:
for access to setup procedures (code for
maintenance staff at the plant)
for the setting up of operating modes (code
for maintenance staff).

Version: 03.00 B

DOSING CONTROL

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL.
DOS. PIPE 80/24mm 13:34:57
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

multi-function key

The display changes to the general SETUP MODE:

F 2 = SETUP

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

From this status - SETUP LOG DATA by


pressing

multi-function key

F1 .

The display changes to the form with operating


instructions.

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

SETUP MODE:

F3

F4

F5

10.03.00
13:34
F = MENU / ESC=back

SETUP of OPERATING DATA for:


F1: LOG DATA .......................=
F2: FILLING INDICATION (SCAN) . ....=
F3: LDT = language /date/time ......=
F4kg-DIAGRAM ............ ..........=
F5: REGULATOR DATA and HEAT-FUNCT.. =
LOG
DATA

F1

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

LOG DATA
0702-B.doc

Version: 03.00 B

3 - 14

07.02

The display changes to the entry form with instructions


(with or without code lock).

ATTENTION:
THESE SETTINGS MAY ONLY BE MADE BY
QUALIFIED AND SPECIFICALLY TRAINED STAFF
ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

10.03.00
SETUP MODE:
13:34:57
LOG DATA
ATTENTION: OPER. INSTRUC. / ESC = back

The display form with instructions for entry of


the code number appears

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

F1

press multi-function key

Enter code number and press


The
SETUP
MODE
for
DATA
and
PARAMETERS is now accessible. The display
changes to the ENTRY FORM.

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

10.03.00
SETUP MODE:
13:34:57
LOG DATA
ATTENTION: OPER. INSTRUC. / ESC = back

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL

F1

Press key
The
SETUP
MODE
for
DATA
and
PARAMETERS is now accessible. The display
changes to the ENTRY FORM.

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
CONTINUE PROCEDURE WITH ENTER

press multi-function key

The display with instructions appears

ENTER data as follows:

Press

Entry: e.g.

or

to move cursor to desired line

...

, press key

and

the LED of the MEMO key is blinking (ready to


save):

proceed with the next entry.

To save data - press key

F1

MEMO and:

MEMORY = YES:

The new values are saved.

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
4 - 14

07.02

0702-B.doc

DATA INPUT:
- The currently valid data is displayed

The display shows the current software version


and the date of the last setup procedures:

K 01 - General data:

Example of entry for WESTOMAT 650:


6

and continue with

ATTENTION
The data entered in K 01 is for information
purposes only and has no influence on the control
of the system.
The settings for the pressure air regulator should
be at 5 bar, and min. 0.5 bar below the actual
operating pressure of the pressure air network.

K 02 - Selection of detection method for dosing


contact (DC):

ATTENTION:

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back
DPC-V1.01-05 = software version
03.03.00
= setup date (K01 / K12)
K01. GENERAL DATA:
123456
= code-N. technician
111
= WESTOMAT type
9999
= product-No
1999
= year of production
000000/99 = Serial No. /Year of ProDos-CPU
85.3.111 = No. electric plan
12.8-0.363= pneumatic-plan-No.
11.1
mm = diaphragm prop-valve
11.1
mm = diaphragm bypass-valve
10.0 bar = oper. press. pr. air supply
4.0
bar = setup pressure regulator
1999
mm = launder length
SERVICE-TELEPHONE STRIKOWESTOFEN
+49(0)6134 = weekdays: 8 to 17 oclock
207883
+49(0)2261
7091140
+49(0)2261 = 24-hours HOTLINE
7091129
K02. DOSING CONTACT (DC) WITH:

ELECTRODE or PneuCo can only be selected


here, if the respective actual devices are installed.
Prior to these settings, set the switch in the
WESTOMAT control cabinet to the respective
position (ELECTRODE / PneuCo).

Enter = 1 - for DC detection at dosing pipe with


ELECTRODE scanning, according to furnace
equipment

Enter = 0 - for DC detection at dosing pipe with


PneuCo, according to furnace equipment

= (Electrode = 1 / PneuCo = 0)

- Example of entry for electrode:

and continue with

Time of DC detection after deaeration:


ATTENTION:
In addition to, and independent from the DC
detection (with ELECTRODE or PneuCo), the
entered value also determines the END of the
metal feed after completed dosing process.

2.5

s = t5-DC (DC after deaeration)

- STANDARD value = 2.5 sec


- MIN. value = 2.0 sec
- MAX. value = 3.5 sec
- Example of entry: 2.5:
INFO

and continue with

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

LOG DATA
0702-B.doc

Version: 03.00 B

5 - 14

07.02

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back
K03. FURNACE FIL: LEVEL DETECTION WITH:

K 03 - Selection of furnace filling level detection:

ATTENTION:
The option cell may only be selected, if a LOAD
CELL (CELL) is actually installed and fully
operational. Please note that the display options for
the furnace filling level are specific for each device.

Enter = 1 - according to furnace equipment,


furnace filling level detection with load cell
(CELL)

Enter = 0 - according to furnace equipment,


furnace filling level detection with hydraulicpneumatic pressure detection system (HPDE)

= (CELL = 1 / HPDE = 0)

- Example of entry for HPDE:

and continue with

K 04 - Selection of temperature regulator:

ATTENTION:
The option for EXTERNAL regulator may only be
selected if this device is actually installed and fully
operational. A change from EXTERNAL to
INTERNAL regulator requires a rewiring of the
thermocouple connections and heating capacity
circuit at the Pro Dos DPC.

K04. TEMPERATURE REGULATION:

Enter = 1 - according to switch cabinet


equipment, for INTERNAL Pro Dos DPC
temperature regulator

Enter = 0 - according to switch cabinet


equipment, for INTERNAL ProDos DPC
temperature regulator

= (INTERN = 1 / EXTERN = 0)

- Example of entry for INTERN temp. regulator:

and continue with

For INTERN regulator:


temperature:
- Enter = 1 - in C
- Enter = 0 - in F
- Example of entry C:

= (C = 1 / F = 0)

INFO

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

and continue with

select

unit

for

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
6 - 14

07.02

0702-B.doc

K 05 - Data of furnace chamber measuring


pressure converter:

ATTENTION:

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back

For the Pro Dos DPC, the displayed limit


measuring ranges (nominal operating pressure PN) of the measuring pressure converter are
permitted: Enter the PN value suitable for the
installed device. Incorrect entries are ignored.

K05. MEASURING PRESSURE CONVERTER (P/I):

Enter = 0 - for furnace chamber measuring


pressure converter with standard measuring
range of 200 mbar

Enter = 1 - for furnace chamber measuring


pressure converter with measuring range of 250
mbar

= nominal operat. press. (Pn)


(200mbar = 0 / 250mbar = 1)

- Example of entry for INTERN temp. regulator:

and continue with

and entry of the standard zero signal:

4.00

mA = Zero-point I-Signal

20.00

mA = I-signal at Pn-mbar

- STANDARD value = 4 mA

ATTENTION:
Any other entered values are ignored.
Example of entry for 4 mA:

and continue with

and entry of the standard zero signal:


- STANDARD value = 20 mA

ATTENTION:
Any other entered values are ignored.
Example of entry for 20 mA:

and continue with

K 06 - Data of furnace chamber pressure:


ATTENTION:
If the feed pressure is to be modified at a later
stage,
the
setup
procedure
for
P/t-MINMEASURING and for kg-DIAGRAM must be
repeated. Values below 40 and above 100 mbar
are not permitted.

K06. PRESSURE FURNACE CHAMBER:

maximum FEED PRESSURE after DC - in


furnace chamber during dosing:
- STANDARD value = 60 mbar
- MIN. value = 40 mbar
- MAX. value = 80 mbar

80

mbar = MAX-feed press. (after P-DC)

Example of entry for 80 mbar:

0 and continue with

INFO

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

LOG DATA
0702-B.doc

Version: 03.00 B

10.03.00
SETUP MODE:
13:34:57
LOG DATA
,
INPUT,
ENTER
and
MEMO / ESC=back

K06. PRESSURE FURNACE CHAMBER: continued


10

mbar = TOP-STOP-pres. below P-DC

7 - 14

07.02

Pressure difference between furnace pressure


at DC (during dosing) and pressure of TOPSTOP HOLDING:

ATTENTION:
In the case of
DC detection by means of
ELECTRODE, the scanning position must be
adjusted in such a manner (15 mm - longitudinal to
electrode axis - below the outlet edge of the dosing
pipe) that there is no metal flow during operating
modes TOP-STOP and LEVEL-SCANNING. Values
below 5 and above 20 mbar are not permitted.
- STANDARD value = 10 mbar
- MIN. value = 5 mbar
- MAX. value = 20 mbar
Example of entry for 10 mbar:

and continue with

Maximum furnace DOSING PRESSURE (total


195

pressure) during dosing process = switching


threshold
for
DISTURBANCE
FURNACE
CHAMBER OVERPRESSURE (AI-04):

mbar = MAX-dosing pres.-DISTURB

ATTENTION:
Values above 200 mbar are not permitted.
- STANDARD value = 195 mbar
- MIN. value = 190 mbar
- MAX. value = 200 mbar
Example of entry for 195 mbar:

240

INFO

mm = MAX-bath height difference

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

and continue with

Maximum BATH HEIGHT DIFFERENCE of the


furnace operat. filling level = for calculation of
switching
threshold
for
DISTURBANCE
FURNACE EMPTY (with level scanning by
means of HPDE):

ATTENTION:
Values other than those in the table are not
permitted.
- STANDARD value = according to table
- MIN./MAX. value = according to table
MAX-BATH HEIGHT DIFFERENCE = STANDARD
VALUES
(in mm) for WESTOMAT model

STANDARD
MIN
MAX

450

650
900

1200

1700

2300

3100

180

220

250

300

300

350

160
200

200
240

230
270

280
320

280
320

330
370

- Example of entry for 200:

and continue with

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
8 - 14

07.02

0702-B.doc

FURNACE
CHAMBER
CORRECTION:
compensation of dosing volume for gradually
emptied furnace:

ATTENTION:

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back
K06. PRESSURE FURNACE CHAMBER: continued

In the event of a dosing volume increase, a smaller


percentage value must be entered. In the event of
dosing volume decrease, a larger percentage value
must be entered for this correction. Adjustments up
to 10 percentage points are permitted.
- STANDARD value = 25 %
- MIN. value = 1 %
- MAX. value = 99 %

25.0

% = furnace chamber-CORRECTION

- Example of entry for 25 %:

and continue with

COUNTER CORRECTION: for compensation of


dosing volume during operation with pressurefree furnace chamber (e.g. without TOP-STOP):

-30.0

% = counter-CORRECTION

ATTENTION:
In the event of a dosing volume increase, a smaller
percentage value (e.g. - 40% instead of - 30%)
must be entered. In the event of a dosing volume
decrease, a larger percentage value (e.g. - 20%
instead of - 30%) must be entered for this
correction. Adjustments up to 10 percentage points
are permitted.
- STANDARD value = -30 %
- MIN. value = -1 %
- MAX. value = -99 %
- Example of entry for -30 %:

0 and continue with

DOSING
CONTACT
CORRECTION:
compensation of dosing volumes during
operation with higher pressure ramps to DC (to
be available soon):
- STANDARD value = 0 %

% = dosing contact-CORRECTION

- Example of entry for 0 %:

and continue with

K 07 - Data of furnace chamber pressure regulator


circuit:

K07. PRES. REG. CIRCUIT FURNACE CHAMBER:

10.00

PROPORTIONAL PART P1 for regulation of


furnace chamber pressure prior to DC:

ATTENTION:

INFO

Values below 5 or above 20 are not permitted.


- STANDARD value = 10
- Example of entry for 10:

and continue with

= P1-contents regulator
FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

LOG DATA
0702-B.doc

Version: 03.00 B

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back

9 - 14

07.02

PROPORTIONAL PART P2 for regulation of


furnace chamber pressure after DC:

ATTENTION:
Values below 10 or above 30 are not permitted.

K07. PRES. REG. CIRC. FURN. CHAMB.: cont.


20.00
= P2-cont. regul. (after DC)

- STANDARD value = 20
- Example of entry for 10:

10.00

s = integral action time

and continue with

READJUSTMENT TIME (I-part) for regulation of


the furnace chamber pressure:

ATTENTION:
Values below 1 or above 10 are not permitted.
- STANDARD value = 2
- Example of entry for 2:

15.0

K 08 - Data on rates of pressure rise in furnace


chamber:

K08. SPEED OF PRESSURE RISE:


= ramp-DC (in mbar/s)

and continue with

PRESSURE RAMP R-DC for pressure increase


from pressure-free furnace chamber to dosing
contact (DC):

ATTENTION:
If this value is to be modified at a later stage, the
setup procedure for P/t-MIN-MEASURING and for
kg-DIAGRAM must be repeated. Values below 10
and above 20 are not permitted.
- STANDARD value = 15 mbar / sec
- MIN. value = 10 mbar / sec
- MAX. value = 20 mbar / sec
Example of entry for 15 mbar / sec:

7.5

INFO

= ramp-DOSING (in mbar/s)

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

and continue with

PRESSURE RAMP R-DC for pressure increase


from TOP-STOP holding pressure to dosing
contact (DC):

ATTENTION:
If this value is to be modified at a later stage, the
setup procedure for P/t-MIN-MEASURING and for
kg-DIAGRAM must be repeated. Values below 5
and above 10 mbar are not permitted.
- STANDARD value = 7.5 mbar / sec
- MIN. value = 5 mbar / sec
- MAX. value = 10 mbar / sec
Example of entry for 7.5 mbar / sec:

and continue

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
10 - 14

07.02

0702-B.doc

Version: 03.00 B

K 09 - Data of DOSING PIPE NO 1:

DOSING PIPES:
Intern. diameter / nozzle bore and min. melt level in pipe
(mm)
- INTERN.
- NOZZLE

40
12/16

50
18

65
21

80
24/28

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back
K09. DOSING PIPE-NO 1:

100
35

min. level
ATTENTION:
The entered diameter must correspond with the
actual diameter of the installed dosing pipe. The
entry of other values results in differences of the
dosing volume. If this value is to be modified at a
later stage, the setup procedure for P/t-MINMEASURING and for kg-DIAGRAM must be
repeated.

INTERNAL DIAMETER:
- STANDARD value = according to table

65

mm = inner diameter

21

mm = nozzle bore

199

mm = MIN-ris. h.w/h dos. pipe

- Example of entry for 65 mm:

and continue with

NOZZLE BORE:

ATTENTION:
The entered diameter must correspond with the
actual bore of the installed dosing pipe. The entry
of other values results in differences of the dosing
volume. If this value is to be modified at a later
stage,
the
setup
procedure
for
P/t-MINMEASURING and for kg-DIAGRAM must be
repeated.
- STANDARD value = according to table
- Example of entry for 21 mm:

1 and continue with

MIN. RISING HEIGHT of melt in dosing pipe at


filling level FURNACE FULL (100 %) and with
pressure-free furnace chamber. The height is
measured from the melt surface to the outlet
edge of the dosing pipe:

ATTENTION:
The measurement must be taken and entered with
an accuracy of 5 mm (!).
- STANDARD value = according to table
- Example of entry for 145 mm:

and continue with

INFO

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

LOG DATA
0702-B.doc

Version: 03.00 B

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back

K10. DOSING PIPE-NO 2:


0
mm = inner diameter
0
mm = nozzle bore
0
mm = MIN-ris. h.w/h dos. pipe

11 - 14

07.02

K 10 - Data of DOSING PIPE NO 2:

Proceed as described for DOSING PIPE NO 1.

ATTENTION:
The data for DOSING PIPE NO 2 must only be
entered if the unit is equipped with a second dosing
pipe and if this pipe is actually used for dosing (i.e.
kg-DIAGRAM).

K11. DOSING SYNCHRONIZATION WITH DCM:


3

n = after n-AUTO-dosing cycles

K 11 - Data for synchronization of the WESTOMAT


processes with the DCM:

n-VALUE (counter of AUTO-ASYNCHRON


dosing processes): in operating mode TOPSTOP and SYNCHRONIZATION ACTIVATED,
and after completion of n AUTO-dosing
processes in series, the subsequent processes
are synchronized. The pressure START for
dosing is carried out in coordination with the
closing of the DCM die, shortening the cycle
time:

ATTENTION:
After each START of the AUTO-dosing mode (after
switching
from
MANUAL
to
AUTO,
after
disturbances, etc.), the n asynchron. dosing
procedures are repeated.
- STANDARD value = 3
- MIN. value = 1
- MAX. value = 9
- Example of entry for -3:

0.50

INFO

s = fill in from DCM-clearing


up to DC (start fill-in)

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

and continue with

SYNCHRONIZATION TIME t 1 (only in AUTOSYNCHRON dosing): In operating mode TOPSTOP


and
with
SYNCHRONIZATION
ACTIVATED, t 1 is calculated in such a way that
the metal feed (of DC) is delayed by this value
from the synchronizing signal of the DCM (e.g.
DIE CLOSED) = Auto-optimisation of cycle time:

ATTENTION:
Values below 0.5 sec often result in process
disturbances:
- DC BEFORE DIE CLOSED and
larger values result in longer cycle times per cast.
- STANDARD value = 0.5 sec
- MIN. value = 0.3 sec
- MAX. value = 1.5 sec
- Example of entry for - 0.5:

and continue

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
12 - 14

07.02

0702-B.doc

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
LOG DATA
, INPUT, ENTER and MEMO / ESC=back

K 12 - CODE LOCKS:

K12. CODE LOCK FOR SETUP MODE:

CODE LOCK for SETUP MODE and for the


configuration of the OPERATING MODES

******

= code No for setup mode S.M.

******

= code No for OPERATING MODES

ATTENTION:
The code lock is designed to prevent unauthorised
modification of the BASIC SETTINGS of the
Pro Dos DPC. The code number is also required
to set up the OPERATING OPTIONS.
- Value = 0 - no code lock .... !!!
- Values = 1 to 999999 - code lock
- Example of entry for 157:

and continue with

CODE LOCK for the SETUP of the OPERATING


MODES:

ATTENTION:
This code lock is designed to prevent unauthorised
modifications of the settings for the various
OPERATING OPTIONS (TOP-STOP, LEVELSCANNING, SYNCHRONIZATION, EMERGENCY
HEATING) of the Pro Dos DPC. The setup mode
for the BASIC SETTINGS is not accessible with the
code lock.

INFO

FILL
LEVEL

LDTSETUP

CYCLE
DATA

SETUP
DATA

- Value = 0 - no code lock .... !!!


- Values = 1 to 999999 - code lock
- Example of entry for 727:

and continue with

The entry of the LOG DATA is now completed:

The display changes to display mode (see


instruction line) and shows the data of all
setup procedures

10.03.00
SETUP MODE:
13:34:57
LOG DATA
= LIST TEXT / MEMO / ESC=back
K13. DISPLAY MODE (lamps):
03.03.00
= setup date
NO 1 = FURNACE FULL - lamps ON

The entered LOG DATA must be saved.

K14. SWITCHING THRESHOLD (lamps):


03.03.00
= setup date
INFO

SETUP MODE

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

LOG DATA
0702-B.doc

Version: 03.00 B

13 - 14

07.02

SAVING LOG DATA


10.03.00
SETUP MODE:
13:34:54
LOG DATA
ATTENTION: DATA HAVE BEEN MODIFIED!

the LED of the MEMO key is blinking (ready to


save):
ATTENTION:

F1 - SAVE DATA MODIFICATION

If only one parameter (i.e. one file) has been


modified, the changes can be saved immediately
after entry.

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

To save data - press key

MEMORY
= NO

BACK TO
ENTRY

F1

F1

F2

F3

F4

F5

MEMORY = YES:

The new values are saved

F3

MEMO and:

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup of the LOG DATA is now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

LOG DATA
07.02

14 - 14

0702-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SET-UP MODE

0703-B.doc

Version: 03.00 B

1-4

REGULATOR HEATING (GENERAL)

07.03

According to the individual specifications, the


WESTOMAT is equipped with a regulator for the
furnace heating and the melt temperature. There are
two options:

in Pro Dos DPC integrated temperature regulator


(see LOG K04 - 1 = INTERN) (standard option) or

external temperature regulator (see LOG K04 - 0 =


EXTERN).

The operating parameters of the Pro Dos DPC


temperature regulator are entered in the setup for the
REGULATOR HEATING and the following setup
procedures:

REGULATOR CONFIGURATION
07.03.1

WEEKEND TEMPERATURE REDUCTION See


chapter 07.03.2

FIRST WARM-UP see chapter 07.03.3

see

chapter

REGULATOR CONFIGURATION
The following standard values for the configuration are
already entered in the software:

switching thresholds from PART. LOAD to FULL to


OFF of the furnace heating

max. furnace temperature

operating parameters for EMERGENCY HEATING


of the furnace (defective thermocouple melt)

The following parameters must be adjusted to the


actual requirements of the operator:

NOMINAL VALUE of melt temperature

Limit values for monitoring of overtemperature and


undertemperature of the melt

Limit

values
for
disturbance
monitoring
(DISTURBANCE: HEATING ALARM) for critical
values for undertemperature and overtemperature
of the melt

Temperature offset (in the event of a deviation of


the temperature indication).

The setup date of the saved data are entered in the


LOG K27. Setup instructions - see chapter 07.03.1.

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REGULATOR HEATING (GENERAL)


07.03

2-4

0703-B.doc

Version: 03.00 B

DOSING CONTROL

WEEKEND TEMPERATURE REDUCTION


The operating parameters for weekend temperature
reduction must be entered according to the
requirements of the operator (see chapter 02.05 Operating Modes):

Day and time for start of temperature reduction

T - value by which temperature is to be reduced


(min. reduced temperature = 650C).

The setup date of the saved data are entered in LOG


K25. Setup instructions - see chapter 07.03.2.
INITIAL WARM-UP
For the initial warm-up, (or renewed cold start of the
furnace) the respective warm-up program must be
selected and subsequently activated:

Warm-up in 4h + 20h

4h with partial load only and up to 400C and


20h with full and partial load to operating
temperature of melt.

The short program may only be selected, if the


fire resistant lining is absolutely dry (not to be
selected after transport or storage of furnace).

Warm-up in 28h + 20h

28h with partial load only and up to 400C and


20h with full and partial load to operating
temperature of melt:

standard program

Warm-up in 52h + 20h

52h with partial load only and up to 400C and


20h with full and partial load to operating
temperature of melt.

The long program option is to be used if the fire


resistant lining is not completely dry (e.g. after
transport or storage of the furnace).

The setup date and the completion of the warm-up are


in LOG K26. Setup instructions - see chapter 07.03.3.
SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS ***


10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

multi-function key

F 2 = SETUP

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE:

SET-UP MODE

REGULATOR HEATING (GENERAL)


0703-B.doc

Version: 03.00 B

10.03.00
13:34
F = MENU / ESC=back

The display changes to selection mode of the


general SETUP MODE:

=
=
=
=
=

values of the individual setup options:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
SETUP
LEVEL
GRAM
HEATING

Select - REGULATOR HEATING by pressing


multi-function key

F1

F2

F3

F4

07.03

The visualisation field shows the currently saved

SETUP of OPERATING DATA for:


F1: LOG DATA ......................
F2: FILLING INDICATION (SCAN)......
F3: LDT = LANGUAGE/DATE/TIME ......
F4: kg-DIAGRAM ....................
F5: REGULATOR DATA and HEAT-FUNCT..
LOG
DATA

3-4

F5 .

F5
The display changes to selection mode of the
REGULATOR HEATING SETUP:

10.03.00
SETUP MODE:
13:34:57
REGULATOR-HEATING
Fx = SETUP / ESC=back
F3 = FIRST WARM-UP (COLD START)

- Activate REGULATOR CONFIGURATION =


press

F4 = REDUCTION TEMPERATURE (MELT)

multi-function key

F5 = REGULATOR CONFIGURATION
INFO
FIRST
T-REDWARM-UP UCTION

- T-REDUCTION

F1

F2

F3

F4

CONFIGUR.
REGULAT.

multi-function key

F5

F5 .
= press

F4 .

- FIRST WARM-UP
multi-function key

= press

F3 .

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

press multi-function key

F1

The display form with instructions for entry of


the code number appears.

Enter code number and press


The SETUP MODE for the respective settings is
now accessible.

SETUP MODE

REGULATOR HEATING (GENERAL)


0703-B.doc

4-4

07.03

Version: 03.00 B

If the SETUP MODE is not code-locked,

The display form with instructions appears.

Press key

the

respective

To enter settings, proceed as follows and complete


procedure by saving entries:
Press

Entry: e.g.

or

to move cursor to desired line


...

, press key

and

the LED of the MEMO key is blinking (ready to


save):

proceed with the next entry.

To save data - press key

F1

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL

The SETUP MODE for


settings is now accessible.

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
ATTENTION: OPER. INSTRUC. / ESC = back

F?

press multi-function key

WESTOMAT P ro Dos DPC


OPERATING MANUAL

MEMO and:

MEMORY = YES:

The new values are saved

CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING
07031-B.doc

Version: 03.00 B

1-8

REGULATOR CONFIGURATION

07.03.1

In the REGULATOR CONFIGURATION setup, the


following data and operating parameters for the
INTERNAL temperature regulator of the Pro Dos
DPC are to be entered:

Data for switching of WESTOMAT furnace heating


and control of the melt temperature

Data for switching of the WESTOMAT furnace


heating EMERGENCY HEATING operation, if
temperature is only monitored by the furnace
chamber thermocouple

The setup date of the REGULATOR CONFIGURATION


is entered automatically in the LOG K 27.
SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key F 2 = SETUP

The display changes to selection mode of the


general SETUP MODE:

The visualisation field shows the currently saved


SETUP MODE:

SETUP of OPERATING DATA for:


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

F1

values of the individual setup options:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

10.03.00
13:34
F = MENU / ESC=back
=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Select - REGULATOR HEATING by pressing


multi-function key

F5 .

SETUP MODE
REGULATOR HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REGULATOR CONFIGURATION
07031-B.doc

2-8

07.03.1

Version: 03.00 B

The display changes to selection mode of the


REGULATOR HEATING SETUP:

Select pressing

REGULATOR

CONFIGURATION

by

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
REGULATOR-HEATING
Fx = SETUP / ESC=back
F3 = FIRST WARM-UP (COLD START)
F4 = REDUCTION TEMPERATURE (MELT)
F5 = REGULATOR CONFIGURATION
INFO
FIRST
T-REDWARM-UP UCTION

F5 .

multi-function key

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

F1

F2

F3

F4

CONFIGUR
.
REGULAT

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

F5

press multi-function key

The display form with instructions for entry of


the code number appears

10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

Enter code number and press


The SETUP MODE for the respective settings is
now accessible.

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F5

The display form with instructions appears.

Press key

The SETUP MODE for


settings is now accessible.

the

respective

Press

or

Entry: e.g.

CONTINUE PROCEDURE WITH ENTER

to move cursor to desired line


...

, press key

and

the LED of the MEMO key is blinking (ready to


save):

proceed with the next entry.

To save data - press key

F1

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL

ENTER data as follows:

10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
ATTENTION: OPER. INSTRUC. / ESC = back

MEMO and:

MEMORY = YES:

The new values are saved.

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING

REGULATOR CONFIGURATION
07031-B.doc

Version: 03.00 B

3-8

07.03.1

DATA INPUT:
10.03.00
SETUP MODE:
13:34:42
REGULATOR CONFIGUR.
, INPUT, ENTER and MEMO / ESC=back

- The existing data (for K 27 and last setup date)


are displayed:

ATTENTION

K27. REGULATOR CONFIGUR.(TEMPERATURE)


12.03.99

The following values for the individual parameters


must be entered. Deviating values might result in
temperature fluctuations and disruptions of the
heating.

= setup date

95

= Xp

Proportional range

X P - PROPORTIONAL RANGE:

Example of entry = 95:


9

s = Tv

Example of entry = 0:

Rate time

s = Tn

Example of entry = 10:

Readjustment time

s = Tsd

and continue with

T N - READJUSTMENT TIME:

and continue with

T V - RATE TIME:

10

0 and continue with

T SD - DELAY TIME for switching of heating from


FULL to PARTIAL LOAD:

Example of entry = 2:

Delay FULL/PARTIAL

and continue with

C Y1 - MINIMUM DURATION HEATING OFF:

Example of entry = 5:
5

s = Cy1 MIN duration heating OFF

and continue with

C Y2 - MINIMUM DURATION HEATING ON:

Example of entry = 5:
5
5

s = Cy2 MIN duration heating ON

and continue with

T SH-MIN - TOGGLING
PARTIAL LOAD:

Example of entry = 4:
4

= Xshmin Toggling FULL/PARTIAL:


INFO

and continue with

TIME

from

FULL

to

SETUP MODE
REGULATOR HEATING

REGULATOR CONFIGURATION
4-8

07.03.1

07031-B.doc

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:56
REGULATOR CONFIGUR.
,
INPUT,
ENTER
and
MEMO / ESC=back

K27. REGULATOR CONFIGUR.(TEMPERATURE)


T SH-MAX - TOGGLING TIME from PARTIAL
FULL LOAD:

to

= Xshmin Toggling FULL/PARTIAL:

= XsdAL1 Hyst. undertemp.

= XsdAL2 Hyst. overtemp. melt

Example of entry = 5:
5

and continue with

X SD-AL1 - HYSTERESIS for the monitoring of the


MELT UNDERTEMPERATURE and the activation of
the DISTURBANCE (dosing locked):

melt

Example of entry = 1:
1

and continue with

X SD-AL1 - HYSTERESIS for the monitoring of the


MELT OVERTEMPERATURE and the activation of
the DISTURBANCE (dosing locked):

Example of entry = 1:
1

and continue with

TEMPERATURE OFFSET - with + or - :

ATTENTION
This entry is only required if the thermocouple of
the melt deviates from the values of a calibrated
measuring device.

= Temperature-Offset

Example of entry = 1:
1

and continue with

AL 3 - Switching threshold for the furnace chamber


temperature
monitoring,
the
DISTURBANCE
OVERTEMPERATURE
FURNACE
CHAMBER
(dosing locked) and HEATING OFF, and the signal
O-08 = HEATING ALARM:

Example of entry = 875 (standard value):


8

875

= AL3 Furnace chamber

and continue with

X SD- AL 3 - HYSTERESIS for the monitoring of the


switching threshold for OVERTEMPERATURE
FURNACE CHAMBER:

Example of entry = 5: (standard value)


5

and continue with

5
= XsdAL3 Hyst. furnace chamb.
temp.
INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING

REGULATOR CONFIGURATION
07031-B.doc

10.03.00
SETUP MODE:
13:34
REGULATOR CONFIGUR.
, INPUT, ENTER and MEMO / ESC=back

Version: 03.00 B

K27. REGULATOR CONFIGUR.(TEMPERATURE)

5-8

07.03.1

AL -08-HEATING OVERTEMPERATURE Switching


threshold for the monitoring of the critical
overtemperature (overheating due to defective
heating system, loss of quality) of the melt, the
DISTURBANCE HEATING ALARM (dosing locked),
HEATING OFF, and the error signal O-08 = from 1
to 0:

lowest permitted value = 725 C

highest permitted value = 855 C

Example of entry = 750:


750

= AL-08-HEATING-overtemperature

and continue with

AL -08-HEATING UNDERTEMPERATURE Switching


threshold for the monitoring of the critical
overtemperature (risk of solidifying due to defective
heating system, loss of quality) of the melt, the
DISTURBANCE HEATING ALARM (dosing locked),
and the error signal O-08 = from 1 to 0:

smallest permitted value = 575 C

highest permitted value = 700 C

Example of entry = 640:


6
640

and continue with

= AL-08-HEATING-undertemperature

EMERGENCY HEATING
ATTENTION
EMERG.-operation via thermocouple

The EMERGENCY HEATING is only available (e.g.


during temporary failure of melt thermocouple), if
this option has been selected. The determining
value for the switching of the heating is the entered
NOMINAL VALUE for the melt, while the
temperature is only monitored by the furnace
chamber thermocouple.
During EMERGENCY HEATING, the 7 segment
displays of the ACTUAL melt temperature (X) are
blinking. The displayed -value does not
correspond with the actual temperature!

From FULL to PARTIAL LOAD - switching


threshold of heating at increasing furnace
chamber temperature:

Example of entry = 20 (above entered


NOMINAL value for the melt):

2
20

= from FULL to PARTIAL LOAD

INFO

0 and continue with

SETUP MODE
REGULATOR HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REGULATOR CONFIGURATION
6-8

07.03.1

07031-B.doc

At PARTIAL LOAD while HEATING is OFF switching threshold of heating at increasing


furnace chamber temperature:

Example of entry = 50 (above entered

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34
REGULATOR CONFIGUR.
,
INPUT,
ENTER
and
MEMO / ESC=back

K27. REGULATOR CONFIGUR.(TEMPERATURE)


50

= at part. load OFF

35

= OFF to part. load

= part. to full load

NOMINAL value for the melt):

and continue with

From HEATING OFF to PARTIAL LOAD switching threshold of heating at decreasing


furnace chamber temperature:

Example of entry = 35 (above entered


NOMINAL value for the melt):

and continue with

From PARTIAL to FULL LOAD - switching


threshold of heating at increasing furnace
chamber temperature:

Example of entry = 5 (above entered


NOMINAL value for the melt):

and continue with


INFO

The entry procedure for the REGULATOR


CONFIGURATION is herewith completed:

The entered LOG DATA must be saved.

SAVING REGULATOR CONFIGURATION


- the LED of the MEMO key is blinking (ready to save):
ATTENTION
If only one parameter (i.e. one file) has been
modified, the changes can be saved immediately
after entry.

To save data - press key

F1

MEMO and:

MEMORY = YES:

The new values are saved

10.03.00
SETUP MODE:
13:34:54
REGULATOR CONFIGUR.
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

F3

SETUP MODE
REGULATOR HEATING

REGULATOR CONFIGURATION
07031-B.doc

Version: 03.00 B

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The
setup
procedure
for
the
CONFIGURATION is now completed.

REGULATOR

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

7-8

07.03.1

SETUP MODE
REGULATOR HEATING

REGULATOR CONFIGURATION
07.03.1

8-8

07031-B.doc

blank page

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATION HEATING
07032-B.doc

Version: 03.00 B

1-4

TEMPERATURE REDUCTION

07.03.2

The functions of the INTERNAL temperature regulation


of Pro Dos DPC include the operating mode
WEEKEND REDUCTION of the holding temperature of
the melt. The function is activated by selecting the
respective operating mode.
In the setup for the TEMPERATURE REDUCTION, the
following operating parameters for WEEKEND
REDUCTION must be entered:

START of
weekday

END of temperature reduction - time and weekday

Value by which temperature is to be reduced


(below nominal value holding temperature)

after consultation with plant operator and


accordance with the companys instructions.

temperature

reduction

time

and

in

The setup date of the TEMPERATURE REDUCTION is


entered automatically in LOG K 25.

SETUP PROCEDURE
- see also chapter 07.00.
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
EXT-KEY DOS-ON or F5 = DOSING
!

In BASIC STATUS of the Pro Dos DPC, press:

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

SETUP MODE:

F3

F4

F5

F1

multi-function key

The display changes to selection mode of the


general SETUP MODE:

The visualisation field shows the currently saved

10.03.00
13:34
F = MENU / ESC=back
=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F 2 = SETUP

values of the individual setup options:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

SETUP of OPERATING DATA for:


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

F5

Select - REGULATOR HEATING by pressing


multi-function key

F5 .

SETUP MODE
REGULATION HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

TEMPERATURE REDUCTION
07032-B.doc

2-4

07.03.2

Version: 03.00 B

The display changes to selection mode of the


REGULATOR HEATING SETUP:

Select - T-REDUCTION by pressing

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:57
REGULATOR-HEATING
Fx = SETUP / ESC=back
F3 = FIRST WARM-UP (COLD START)

multi-function key

F4 .

F4 = REDUCTION TEMPERATURE (MELT)

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

F5 = REGULATOR CONFIGURATION
INFO
FIRST
T-REDWARM-UP UCTION

F1

F2

F3

F4

REGULAT.
CONFIGUR.

F5

Access to this SETUP OPTION can be locked by code


lock.
The
code
lock
prevents
unauthorised
manipulation at the Pro Dos DPC and is recorded in
LOG K 12.
If the SETUP MODE is code-locked,

The display form with instructions for entry of the


code number appears.

10.03.00
SETUP MODE:
13:34:57
TEMPERATURE
REDUCTION
ATTENTION: OPER. INSTRUC. / ESC = back

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL

press multi-function key

F4

Enter code number and press

The SETUP MODE for the respective settings is


now accessible.

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F4

The display form with instructions appears.

Press key

10.03.00
SETUP MODE:
13:34:57
TEMPERATURE RED.
ATTENTION: OPER. INSTRUC. / ESC = back

The SETUP MODE for


settings is now accessible.

the

respective

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL

Enter data as follows:

CONTINUE PROCEDURE WITH ENTER


Press
line.

or

to move cursor to desired

Enter data as follows:

or

for weekday

- the LED of the MEMO key is blinking (ready to


save):

...

for hour / minute / C

Press MEMO to save:

F 1 MEMORY=YES

WESTOMAT ProDos DPC


OPERATION MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING

TEMPERATURE REDUCTION
07032-B.doc

Version: 03.00 B

3-4

07.03.2

DATA INPUT:
10.03.00
SETUP MODE:
13:34:54
TEMPERATURE RED.
, MODIFY +,- AND ENTER / ESC=back

- Previously entered data for K25 is displayed:

K25. TEMPERATURE REDUCTION (MELT)

If temperature reduction is activated, dosing cannot


be carried out. The programme times and the value for the reduction are only to be entered in
accordance with the instructions of the operator.

ATTENTION

Values for the temperature reduction (in C) that


are below the calculated nominal value of 625 C
are not permitted and result in an ERROR! ENTRY
VALUE! message.

SATURDAY

START of REDUCTION:
- select weekday by pressing

= start of reduction

or

for weekday, to

display next / previous weekday.

23:30

Enter hour / minutes as follows:


- Example of entry for 23:30 hours:

04:30

and

for hours;

...

and

for minutes.

or

for weekday, to

Enter hour / minutes as follows:


- Example of entry for 04:30 hours:

...

and

for hour;

...

and

for minutes.

= time

REDUCTION TEMPERATURE:
- Example of entry = 65 (below NOMINAL value):

INFO

display next / previous weekday.

= end of reduction

-65

...

END of REDUCTION:
- select weekday by pressing

MONDAY

2
= time

C = Temperature reduction by

and continue with

The entry procedure for the TEMPERATURE


REDUCTION is herewith completed:

The entered data must be saved.

SETUP MODE
REGULATION HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

TEMPERATURE REDUCTION
4-4

07.03.2

07032-B.doc

Version: 03.00 B

DOSING CONTROL

SAVING TEMPERATURE REDUCTION


- the LED of the MEMO key is blinking (ready to
save):
ATTENTION:
If only one parameter (i.e. one file) has been
modified, the changes can be saved immediately
after entry.

To save data - press key

MEMO and:

10.03.00
SETUP MODE:
13:34:54
TEMPERATURE RED.
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION

F1

The new values are saved

F3

MEMORY = YES:

F5 - BACK TO ENTRY

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

MEMORY
= YES

F1

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup procedure for the


REDUCTION is now completed.

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

TEMPERATURE

Press key ESC - display returns to initial status

press key
STATUS.

ESC - display returns to BASIC

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING
07033-B.doc

Version: 03.00 B

FIRST WARM-UP

1-6

07.03.3

The functions of the INTERNAL temperature regulation


of the Pro Dos DPC include the FIRST WARM-UP, a
programme designed to bring the furnace to operating
temperature at commissioning or after it has been shut
down for more than one week. This function is
activated by selecting the respective setup mode.
ATTENTION
Prior to switching on the furnace, ensure that the
following is properly carried out:
installation and acceptance of heating connections.
Attach appropriate warning signs, e.g. HEATING
OPERATION.
In the setup mode for FIRST WARM-UP, select and
activate (or deactivate) the warm-up programme
according to the specific required time:

WARM-UP in 4 h + 20 h (approx. 24 h = FAST):


in 4 h = FIRST stage, four hours of warm-up
operation with partial load only, and to 400C
20 h = twenty warm-up operating hours
(immediately after FIRST warm-up stage) with
partial and full load to the nominal value for the
melt temperature - e.g. 700C

WARM-UP in 28 h + 20 h (approx. 48 h =
STANDARD):
in 28 h = FIRST stage, twenty-eight hours of
warm-up operation with partial load only, and to
400C
20 h = twenty warm-up operating hours
(immediately after FIRST warm-up stage) with
partial and full load to the nominal value for the
melt temperature - e.g. 700C

WARM-UP in 52 h + 20 h (approx. 72 h = SLOW):


in 52 h = FIRST stage, fifty-two hours of warmup operation with partial load only, and to 400C
20 h = twenty warm-up operating hours
(immediately after FIRST warm-up stage) with
partial and full load to the nominal value for the
melt temperature - e.g. 700C

END TEMPERATURE:
End temperature of the warm-up procedure =
NOMINAL value of operating temperature for the
melt (min. temperature = 650C).

At commissioning, the warm-up options of 28 h + 20 h


should be selected. The realization of the FIRST
WARM-UP is automatically entered with the setup date
in LOG K 26.

SETUP MODE
REGULATOR HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FIRST WARM-UP
07.03.3

2-6

07033-B.doc

Version: 03.00 B

DOSING CONTROL

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

multi-function key

The display changes to selection mode of the


general SETUP MODE:

F 2 = SETUP

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

F1

F5 .

F2

SETUP MODE:

F3

F4

F5

10.03.00
HEATING
13:34
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

Select - REGULATOR HEATING by pressing


multi-function key

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

LOG
DATA

F1

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

The display changes to selection mode of the


REGULATOR HEATING SETUP:

Select - FIRST-WARM-UP by pressing


10.03.00
HEATING
SETUP MODE:
13:34
SCAN=CELL
REGULATOR-HEATING
F = MENU / ESC=back
F3 = FIRST WARM-UP (COLD START)
F4 = REDUCTION TEMPERATURE (MELT)
multi-function key

F3 .

F5 = REGULATOR CONFIGURATION
INFO

F1

FIRST
T-REDCONFIGUR.
WARM-UP UNCTION REGULAT.

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING

F I R S T W AR M - U P
07033-B.doc

Version: 03.00 B

3-6

07.03.3

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

10.03.00
HEATING
SETUP MODE:
13:34:57
SCAN=CELL
FIRST WARM-UP
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

F3

The display form with instructions for entry of


the code number appears

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

press multi-function key

Enter code number and press


The SETUP MODE for the activation (or
deactivation) of the FIRST WARM-UP is now
available.

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,


10.03.00
HEATING
SETUP MODE:
13:34:57
SCAN=CELL
FIRST WARM-UP
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL

press multi-function key

F3

The display form with instructions appears

The SETUP MODE for the activation (or


deactivation) of the FIRST WARM-UP is now
available.

CONTINUE PROCEDURE WITH ENTER


... The display changes to the selection form for
the warm-up programmes.
10.03.00
HEATING
SETUP MODE:
13:34:57
SCAN=CELL
FIRST WARM-UP
/ 1 = ON, 0 = OFF / ESC=back
K26. FIRST WARM-UP (COLD START FURNACE):
0 = warm-up in
0 = warm-up in
0 = warm-up in

4h + 20h
28h + 20h
52h + 20h

700C = end temperature


INFO

SETUP MODE
REGULATOR HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FIRST WARM-UP
07033-B.doc

4-6

07.03.3

Version: 03.00 B

DOSING CONTROL

SELECTION and ACTIVATION (DEACTIVATION) of


WARM-UP PROGRAMME:

To select and activate (or deactivate) a warm-up


programme, proceed as follows:

With

or

, set cursor in line

of the desired WARM-UP PROGRAMME.


Continue with
entry of 1 = ACTIVATE programme:

and

- the LED of the MEMO key

is blinking (ready to save).

To save data - press key

F1

MEMO and:

MEMORY = YES:

and ESC = WARM-UP PROGRAMME


is started.

F3

MEMORY = NO:

no modification

F5

10.03.00
HEATING
SETUP MODE:
13:34:54
SCAN=CELL
FIRST WARM-UP
ATTENTION: DATA HAVE BEEN MODIFIED!

BACK TO ENTRY:

to return to entry form.

The FIST WARM-UP programme is now activated.

ATTENTION
The WARM-UP programme is ACTIVATED and

by activating the switch HEATING ON, the


heating is switched on.

The segmented display shows the temperature


values as follows:
X = current ACTUAL value, as measured by
thermocouple melt.
W = NOMINAL value (FIRST stage = 400C)

The cycle counter of the respective stage is


automatically switched on.

After completion of the FIRST stage, the


SECOND stage is automatically initiated.

The remaining operating hours until END of


warm-up procedure is displayed.

After completion of the warm-up programme,


the furnace heating is automatically switched to
normal operation.

F1 - SAVE DATA MODIFICATION


F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

10.03.00
HEATING
SETUP MODE:
13:34:54
SCAN=CELL
FIRST WARM-UP
ACTIVE: FIRST STAGE / ABORT WITH F5
WARM-UP PROGRAM:
- 28 hours until 400C (FIRST stage)
- 20 hours until 700C (SECOND stage)
END WARM-UP:
- a. abt. 21.5 operating hours
LDTSETUP

LOG
DATA

F1

F2

F3

REGULAT.
HEATING

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
REGULATOR HEATING

F I R S T W AR M - U P
07033-B.doc

Version: 03.00 B

5-6

07.03.3

Entry of 0 = DEACTIVATE programme:

and

- the LED of the MEMO key

is blinking (ready to save).

To save data - press key

F1

MEMO and:

MEMORY = YES:

Press ESC = WARM-UP


PROGRAMME
is terminated.

F3

no modification

F5

MEMORY = NO:

BACK TO ENTRY:

to return to entry form.

The FIRST
deactivated.

WARM-UP

programme

is

now

SETUP MODE
REGULATOR HEATING

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FIRST WARM-UP
07.03.3

6-6

07033-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

0704-B.doc

Version: 03.00 B

1-6

FILLING LEVEL DETECTION - GENERAL

07.04

According to the specific equipment of the


WESTOMAT with the ProDos DPC, the furnace
filling level detection is carried out by means of:

The hydraulic-pneumatic pressure detection system


(HPDE), or

the load cell (CELL)

The method for filling level scanning can be selected in


the LOG (see chapter 07.02) of the Pro Dos DPC,
according to the equipment.
The furnace filling level is indicated by lamps mounted
on the furnace and indirectly by the display of the melt
volume (in kg).

ATTENTION
The filling level scanning by means of the CELL
system is activated as soon as the Pro Dos DPC
is switched on and is independent from the
DOSING OPERATION.
The filling level scanning by means of the HPDE
system is only fully activated if the DOSING
OPERATION is switched on (with operating modes
TOP-STOP and LEVEL-SCANNING).
The setup of the filling level scanning system is carried
out prior to the commissioning of the furnace in the
setup mode FILLING LEVEL INDICATION. The two
separate setup modes are as follows:

for the load cell (CELL)


- see chapter 07.04.3

in

in CELL-mA-SIGNAL:
compensation of CELL signal re. operating
modes of furnace
see chapter 07.04.3.2

in chapter P/t-MIN-MEASURING:
measured values for pressure and time at
realization of dosing contact if FURNACE
FULL.
These parameters apply to both CELL and
HPDE system.
see chapter 07.04.3.3

in CELL-SIGNAL COMPENSATION:
subsequent compensation of CELL signal re.
operating modes of furnace
see chapter 07.04.3.4

CELL-DATA ENTRY:
technical data of CELL and
furnace filling level data
see chapter 07.04.3.1

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FILLING LEVEL DETECTION - GENERAL


2-6

07.04

0704-B.doc

Version: 03.00 B

DOSING CONTROL

for the

hydraulic-pneumatic pressure detection


system (HPDE):
- see chapter 07.04.4

in HPDE -DATA ENTRY:

furnace filling level data


cycle time for LEVEL-SCANNING
see chapter 07.04.4.1

in chapter P/t-MIN-MEASURING:

measured values for pressure and time at


realization of dosing contact if FURNACE
FULL.
These parameters apply to both CELL and
HPDE system.
see chapter 07.04.4.2

For both filling level scanning systems, the following


parameters are entered in the setup option FILLING
LEVEL INDICATION:

for DISPLAY MODE (of lamps):

Mode-1: FURNACE FULL = lamps ON


Mode-2: FURNACE FULL = lamps OFF
Mode-3: BATH LEVEL = one lamp ON

see chapter 07.04.1

SWITCHING THRESHOLDS of indictor lamps:


STANDARD
= not modifiable
SELECTED VALUE = modifiable
see chapter 07.04.2

The entered value must be saved.


Subsequent modifications of the setup parameters are
possible and must also be carried out in the FILLING
LEVEL INDICATION setup mode.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

multi-function key

F 2 = SETUP

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE:

SETUP MODE

FILLING LEVEL DETECTION GENERAL


0704-B.doc

Version: 03.00 B

LOG
DATA

F1

=
=
=
=
=

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

07.04

The display changes to the general SETUP MODE:

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

3-6

Select pressing

FILLING

multi-function key

F5

LEVEL

INDICATION

by

F2 .

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in LOG K 12.
If the SETUP MODE is code-locked,

10.03.00
SETUP MODE:
13:34:57
SCAN=CELL
CELL-FILLINGINDICATION
ATTENTION: OPER. INSTRUC. / ESC = back

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL (HPDE) FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
CELL (or HPDE) SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

press multi-function key

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

10.03.00
SETUP MODE:
13:34:57
SCAN=CELL
CELL-FILLINGINDICATION
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

Press
The SETUP MODE for the CELL (HPDE)
FILLING LEVEL INDICATION is now accessible
and the display changes to the selection mode
for the SETUP:
CELL (or HPDE) SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

FILLING LEVEL DETECTION - GENERAL


07.04

0704-B.doc

4-6

Version: 03.00 B

DOSING CONTROL

Continue according to the example below for the


CELL filling level scanning system:
... The display changes to selection mode of the
general SETUP MODE:

F 2 = CELL-SYSTEM
- see chapter 07.04.3

F 4 = DISPLAY MODE
- see chapter 07.04.1

F 5 = SWITCHING THRESHOLDS
- see chapter 07.04.2

In CELL-SYSTEM, press
multi-function key

10.03.00
SETUP MODE:
13:34:51
SCAN=CELL
CELL-FILINGINDICATION
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELLDISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

F5

F2 .

... The display changes to selection mode of the


CELL SETUP:

F 2 = CELL-DATA ENTRY
- see chapter 07.04.3.1

F 3 = CELL-mA-SIGNAL
- see chapter 07.04.3.2

F 4 = chapter P/t-MIN-MEASURING
- see chapter 07.04.3.3

10.03.00
SETUP MODE:
13:34:51
SCAN=CELL
CELL-FILLINGINDICATION
F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup
F4= P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save
F5 = SIGNAL-CORRECT. - setup correction
due to signal modification
INFO
DATACELL-mA P/t-MIN CORRECT.
ENTRY
SIGNAL
MEASURE SIGNAL

F 5 = CELL-SIGNAL-COMPENSATION.
- see chapter 07.04.3.4

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

FILLING LEVEL DETECTION GENERAL


0704-B.doc

Version: 03.00 B

5-6

07.04

... Or continue according to the example below for


the HPDE filling level scanning system:
10.03.00
SETUP MODE:
13:34:51
SCAN=HPDE
HPDE-FILLINGINDICATION
F = MENU / ESC=back
F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

F5

... The display changes to selection mode of the


general SETUP MODE:

F 2 = HPDE-SYSTEM
- see chapter 07.04.4

F 4 = DISPLAY MODE
- see chapter 07.04.1

F 5 = SWITCHING THRESHOLDS
- see chapter 07.04.2

In HPDE-SYSTEM, press
multi-function key

F2 .

... The display changes to selection mode of the


HPDE SETUP:
10.03.00
SETUP MODE:
13:34:51
SCAN=HPDE
HPDE-FILLINGINDICATION
F = MENU / ESC=back
F4 = DATA ENTRY for HPDE-system
F5 = P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save
INFO
DATA
P/t-MIN
ENTRY
MEASURE

F1

F2

F3

F4

F5

F 4 = HPDE-DATA ENTRY
- see chapter 07.04.1

F 5 = chapter P/t-MIN-MEASURING
- see chapter 07.04.2

SETUP MODE

FILLING LEVEL DETECTION - GENERAL


07.04

6-6

0704-B.doc

blank page

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION
07041-B.doc

Version: 03.00 B

1-4

DISPLAY MODE

07.04.1
The lamp column mounted on the WESTOMAT is
controlled by the Pro Dos DPC and indicates the
filling level of the furnace. The display mode for the
lamps can be selected independently of the
WESTOMAT filling level indication system with:

load cell (CELL)

hydraulic-pneumatic pressure detection (HPDE)

The following options are available:

DISPLAY MODE NO 1:
- furnace is full = all lamps switched ON

DISPLAY MODE NO 2:
- furnace is full = all lamps switched OFF

DISPLAY MODE NO 3:
- according to upper edge of melt level in furnace =
only one lamp ON.

The setup date for the DISPLAY MODE of the lamps is


automatically entered in LOG K 13.

SETUP PROCEDURE
- see also chapter 07.00.
ATTENTION
The following example is based on filling level
detection by means of load cell. If a HPDE is used, the
display shows HPDE instead of CELL.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS ***


10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s

DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key

F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DISPLAY MODE
07.04.1

2-4

07041-B.doc

Version: 03.00 B

The display changes to the general SETUP MODE:

SETUP MODE:

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

Select
pressing

FILLING-LEVEL-INDICATION

DOSING CONTROL

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


F1: LOG DATA ......................
F2: FILL LEVEL INDICATION .........
F3: LDT = LANGUAGE/DATE/TIME ......
F4: kg-DIAGRAM ....................
F5: REGULATOR DATA and HEAT-FUNCT..
by
LOG
DATA

multi-function key F 2 .

ATTENTION

F1

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL (HPDE)
FILLING LEVEL INDICATION is now accessible
and the display changes to the selection mode
for the SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
13:34:57
CELL-FILLINGSCAN=CELL
INDICATION
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL (HPDE)
FILLING LEVEL INDICATION is now accessible
and the display changes to the selection mode
for the SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
13:34:57
CELL-FILLINGSCAN=CELL
INDICATION
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT ProDos DPC


OPERATING MANUAL

DISPLAY MODE
07041-B.doc

DOSING CONTROL

Version: 03.00 B

3-4

07.04.1

... The display changes to selection mode.

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back

Select - DISPLAY MODE by pressing

F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F4 .

multi-function key

F1

F2

F3

F4

F5

10.03.00
SETUP MODE:
13:34:54
DISPLAY MODE
, 1=YES, ENTER and MEMO / ESC=back

... The display changes to selection mode.

Mode -1: FURNACE FULL = lamps ON


Mode -2: FURNACE FULL = lamps OFF
Mode -3: BATH LEVEL = one lamp ON

K13. DISPLAY MODE (lamps):

... Press key

1 = MODE 1: FURNACE FULL / lamps ON

to place cursor in MODE line

and press

0 = MODE 2: FURNACE FULL / lamps OFF


0 = MODE 3: BATH LEVEL

or

/ ONE lamp

INFO

and continue with

The

display
completed.

MODE

selection

is

herewith

The entered selection must be saved.

... SAVING ENTERED DATA


- the LED of the MEMO key is blinking (ready to
save):

10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
DISPLAY MODE
ATTENTION: DATA HAVE BEEN MODIFIED!

To save data - press key

F1 - SAVE DATA MODIFICATION

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

F1

F4

F3

F5

MEMORY = YES:

the new selection is saved.

BACK TO
ENTRY

MEMO and:

MEMORY = NO:

The new selection is deleted and the


previous selection remains saved; the
display returns to initial status.

F5

BACK TO ENTRY:

The previous values are overwritten; the


display returns to the entry form, where
the newly entered values are displayed;
additional entries and modifications can
be made.

The setup of the DISPLAY MODE is now completed:

Press key

ESC - display returns to initial status

press key
STATUS.

ESC - display returns to BASIC

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DISPLAY MODE
07.04.1

4-4

07041-B.doc

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION
07042-B.doc

Version: 03.00 B

1-4

SWITCHING THRESHOLDS (of lamps)

07.04.2

The lamp column with five lamps mounted on the


WESTOMAT
indicates the level of the melt
(switching thresholds) in the furnace.
The switching thresholds can be set independently
from the filling level scanning with:

load cell (CELL), or

hydraulic-pneumatic pressure detection (HPDE).

The following options are available:

STANDARD FILLING LEVELS

STANDARD VALUES:
- The switching thresholds (filling levels) of the
lamps are pre-set in the software and cannot be
modified.

O-17 = 100%
O-18 = 92%

O-19 = 69%

SELECTABLE VALUES:
- The switching thresholds (filling levels) of the
lamps can be adjusted to suit the requirements of
the operator and saved.

O-20 = 46%
O-21 = 23%
= 0%

The setup date for the DISPLAY MODE of the lamps is


automatically entered in LOG K 14.

SETUP PROCEDURE
- see also chapter 07.00.
ATTENTION
The following example is based on filling level
detection by means of load cell. If a HPDE is used, the
display shows HPDE instead of CELL.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key

F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT P ro Dos DPC


OPERATING MANUAL

S W I T C H I N G T H R E S H O L D S ( of lamps)
07.04.2

07042-B.doc

2-4

The display changes to the general SETUP MODE:

Version: 03.00 B

SETUP MODE:

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

LOG
DATA

F2 .

10.03.00
HEATING
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

Select - REGULATOR HEATING by pressing


multi-function key

DOSING CONTROL

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

F1

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in LOG K 12.
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

HEATING
10.03.00
SETUP MODE:
SCAN=CELL
13:34:57
CELL-FILLING-INDICA
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

HEATING
10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

S W I T C H I N G T H R E S H O L D S ( of lamps)
07042-B.doc

Version: 03.00 B

3-4

07.04.2

In
this
mode,
activate
THRESHOLD option by pressing

SWITCHING

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

F5

multi-function key

F5 .

... The display changes to the selection mode for


VALUE SELECTION. Press

10.03.00
SETUP MODE:
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
K14. SWITCHING THRESHOLDS (lamps):
F5 = SWITCHING THRESHOLDS: of lamps
(only for ACCORD. TO SELECTION)
INFO

F1

SELECT
VALUES

F2

F3

F4

F5

multi-function key

... The display changes to selection mode for


STANDARD / SELECTABLE VALUES:

... Select SELECTABLE VALUES by pressing:

or

10.03.00
SETUP MODE:
CELL-FILLING-INDICA 13:34:51
, 1=YES, ENTER and MEMO / ESC=back
SELECT: STANDARD or ACCORD. TO SELECT.
1 = STANDARD VALUES (not changeable)
0 = ACCORD. TO SELECT. (changeable)
INFO

The selection is now completed. The selected


option must be saved:
- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

F1 - SAVE DATA MODIFICATION

F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

... The display changes to selection mode.

MEMO and:

MEMORY = YES:

The new values are saved

F3

MEMORY = NO:

The new values are deleted and the


previous values remain saved.

F5

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

to place cursor in desired line

10.03.00
SETUP MODE:
CELL-FILLING-INDICA 13:34:54
ATTENTION: DATA HAVE BEEN MODIFIED!

F5 .

BACK TO ENTRY:

The display returns to initial status and


additional entries and modifications can
be made.

SETUP MODE
FILLING LEVEL INDICATION

WESTOMAT P ro Dos DPC


OPERATING MANUAL

S W I T C H I N G T H R E S H O L D S ( of lamps)
4-4

07.04.2

07042-B.doc

Press multi-function key F 5 to return to


selection.

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
K14. SWITCHING THRESHOLDS (lamps):
F4 = SWITCHING THRESHOLDS: of lamps
(only for ACCORD. TO SELECTION)
F5 = VALUE SELECTION = STANDARD or
ACCORD. TO SELECTION
- values of switching thresholds
INFO

Press multi-function key F 4 and continue with


entry of SELECTABLE VALUES:

- The display shows the standard values or the


previously entered selectable values. Enter new
values:
ATTENTION
The %-value for lamp FURNACE FULL O-17 =
100 % cannot be modified.

F1

SWITCH. SELECT
THRESH. VALUES

F2

F3

F4

F5

SWITCHINGTHRESHOLDS 10.03.00
:fil. evel MODE 1+2 13:34:54
, INPUT, ENTER and MEMO / ESC=back
at
at
at
at

23%
46%
69%
92%
30s

=
=
=
=
=

lamp
lamp
lamp
lamp
lamp

0-21
0-20
0-19
0-18
0-17 delay

100% = 0-17 lamp FURNACE FULL


INFO

After completion of entries, the new values must


be saved:
- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

MEMO and:

MEMORY = YES:

10.03.00
SETUP MODE:
CELL-FILLING-INDICA 13:34:54
ATTENTION: DATA HAVE BEEN MODIFIED!

The new values are saved


F1 - SAVE DATA MODIFICATION

F3

MEMORY = NO:

The new values are deleted and the


previous selection remains saved; the
display returns to initial status.

F5

BACK TO ENTRY:

The previous values are overwritten; the


display returns to the entry form, where
the newly entered values are displayed;
additional entries and modifications can
be made.

The setup of the SWITCHING THRESHOLDS is now


completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

SETUP MODE
FILLING LEVEL INDICATION
07043-B.doc

DOSING CONTROL

Version: 03.00 A

1-4

CELL-FILLING LEVEL SYSTEM - GENERAL

07.04.3

Depending on the WESTOMAT equipment, the filling


level scanning system with load cell (CELL) is
activated in the Pro Dos DPC LOG K 03.
The initial setup of the filling level scanning system is
carried out at commissioning in the setup for FILL
LEVEL INDICATION. Subsequent modifications of the
parameter are also made in this setup option.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

SETUP MODE:

F3

F4

F5

F1

multi-function key

=
=
=
=
=

The visualisation field shows the currently saved

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

F 2 = SETUP

The display changes to the general SETUP MODE:


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

Select - FILL LEVEL INDICATION by pressing


multi-function key

F2 .

SETUP MODE
FILLING LEVEL INDICATION

CELL-FILLING LEVEL SYSTEM - GENERAL


07.04.3

2-4

07043-B.doc

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

... The display changes to selection mode.

Select - CELL SYSTEM by pressing

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system
F4 = DISPLAY MODE of lamps

multi-function key F 2 .

F5 = SWITCHING THRESHOLDS: of lamps


standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION

CELL-FILLING LEVEL SYSTEM - GENERAL


07043-B.doc

Version: 03.00 A

... The display changes to selection mode.

The setup procedures for CELL filling level scanning


must be entered and saved as follows:

CELL -DATA ENTRY:

CELL-mA-SIGNAL:

see chapter 07.04.3.1


technical data of CELL and
furnace filling level data:
kg-values, valid for both CELL and HPDE
system (see chapter 07.04.4.1)

see chapter 07.04.3.2


compensation of CELL signal
operating modes of furnace

re.

actual

in chapter P/t-MIN-MEASURING:

see chapter 07.04.3.3


measured values for pressure and time at
realization of dosing contact if FURNACE FULL

these parameters are valid for both CELL and


HPDE system (see chapter 07.04.4.2)

CELL-SIGNAL COMPENSATION:

see chapter 07.04.3.4


only for subsequent correction of CELL signal in
operating modes of the furnace (not to set up at
commissioning).

The saved data and the setup data are automatically


recorded in LOG K13 to K18.

ATTENTION
During this setup procedure, the filling level
indication of the furnace is deactivated.
After completion of the setup procedure for CELL
filling level indication, the times for CYCLE and
LEVEL SCANNING must be entered in the setup
mode DATA ENTRY for HPDE filling level
indication.

3-4

07.04.3

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup
F4 = P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save
F5 = SIGNAL-CORRECT. - setup correction
due to signal modification
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
mAMEASUR. SIGNAL
SIGNAL:

F1

F2

F3

F4

F5

SETUP MODE
FILLING LEVEL INDICATION

CELL-FILLING LEVEL SYSTEM - GENERAL


07.04.3

4-4

07043-B.doc

blank page

Version: 03.00 A

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION/ CELL
070431-B.doc

Version: 03.00 A

1-6

DATA ENTRY

07.04.3.1

In the Pro Dos DPC setup mode for CELL DATA


ENTRY, the basic data of the WESTOMAT filling
level detection system with load cell (CELL) must be
entered:

FURNACE OPERATING FILLING LEVEL:


- melt volume available for dosing (in kg, also
applicable for HPDE scanning).

REFILL CHARGE:
- when this value (in kg, also applicable for HPDE
scanning) is reached, the signal (O-04) REFILL
CHARGE is automatically activated.
- For reasons of quality, the refill charge should not
exceed approx. 50 % of the operating filling level of
the furnace.

O-04 REFILL ACKNOWLEDGED:


- when this volume (in kg, also applicable for HPDE
scanning) has been refilled, the signal (O-04)
REFILL CHARGE is automatically reset.

CELL NOMINAL LOAD (QN):


- for value, refer to type plate of unit

ZERO POINT SIGNAL CELL:


- mA-signal of CELL without load
- for value, refer to type plate of unit

Signal value of CELL at QN-LOAD:


- mA-signal of CELL with nominal load
- for value, refer to type plate of unit

The setup date of the CELL DATA ENTRY is entered


automatically in LOG K 15.

SETUP PROCEDURE
- see also chapter 07.00.
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 65/21mm 13:34:57
EXT-KEY DOS-ON or F5 = DOSING
!

In BASIC STATUS of the Pro Dos DPC, press:

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F1

F2

F3

F4

F5

multi-function key

F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
07.04.3.1

070431-B.doc

2-6

The display changes to the general SETUP MODE:

Version: 03.00 A

SETUP MODE:

10.03.00
13:34:57

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

Select - FILL LEVEL INDICATION by pressing


multi-function key

F2 .

SCAN=CELL
F = MENU / ESC=back
SETUP of OPERATING DATA for:
F1: LOG DATA ......................
F2: FILL LEVEL INDICATION .........
F3: LDT = LANGUAGE/DATE/TIME ......
F4: kg-DIAGRAM ....................
F5: REGULATOR DATA and HEAT-FUNCT..
LOG
DATA

F1

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

DOSING CONTROL

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in LOG K 12.
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

DATA ENTRY
070431-B.doc

Version: 03.00 A

3-6

07.04.3.1

... The display changes to selection mode.

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system

Select - CELL SYSTEM by pressing

F4 = DISPLAY MODE of lamps


F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.
multi-function key

F1

F2

F3

F4

F2 .

F5

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup

... The display changes to selection mode.

Select - DATA ENTRY by pressing

F4 = P/t-MIN MEASURING : when furn. full:


P-pressure, t-time = measure/save
F5 = SIGNAL-CORRECT. - setup correction
due to signal modification
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
mAMEASUR. SIGNAL
SIGNAL

F1

F2

F3

F4

F2 .

F5

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-DATA ENTRY
, INPUT, ENTER and MEMO / ESC=back
K15. CELL-FILLING INDICATION SYSTEM:
13.09.99

multi-function key

= setup date

... The display changes to entry mode.

DATA ENTRY

kg-FURNACE OPERATING FILLING LEVEL:


FURNACE OPERATING FILLING LEVEL of MELT
(in kg) for WESTOMAT model
450

650

900

1200

1700

2300

3100

300

500

700

900

1400

1800

2450

- Example of entry for 700 kg:

7
700
INFO

kg = fur.operating filling level

and continue with

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
4-6

07.04.3.1

070431-B.doc

kg-REFILL CHARGE:

- The kg-value of the REFILL CHARGE depends


on the size of the refilling and transport devices.
- For reasons of quality, the REFILL CHARGE
should not exceed 50% of the OPERATING
FILLING LEVEL in the furnace.

Version: 03.00 A

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-DATA ENTRY
, INPUT, ENTER and MEMO / ESC=back
K15. CELL-FILLING INDICATION SYSTEM:

- If the furnace is to be emptied, and a filling


level of e.g. 700 300 = 400 kg is reached, O04 = from 0 to 1
- The signal O-04 = 1 REFILL, the complete
refill charge can be filled into the furnace.
- Example of entry for 300:

and continue with


300

kg = refill charge

150

kg = O-04-REFILL ACKNOWLEDGED

O-04 REFILL ACKNOWLEDGED:

- As soon as the furnace is refilled with at least


this volume, e.g. 700 300 + 150 = 550 kg,
signal O-04 = from 1 to 0.
- Example of entry for 150:

and continue with

ATTENTION
Values for:

FURNACE OPERATING FILLING LEVEL:

REFILL CHARGE:

O-04 REFILL ACKNOWLEDGED:

INFO

DIAGRAM OF FURNACE FILLING LEVELS

are automatically transferred to HPDE FILLING


LEVEL (in LOG K 19).

B O-04 = 0 = kg
A O-04 = 1 = kg

MAX-AL = kg
O-17 = 100%
O-18 = 92%
O-19 = 69%
O-20 = 46%
O-21 = 23%
= 0%

O-04

1
0

MAX-AL = FURN. OPERAT. FILLING LEVEL


A
= REFILL CHARGE
B
= O-04-REFILL ACKNOWLEDGED

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

DATA ENTRY
070431-B.doc

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-DATA ENTRY
, INPUT, ENTER and MEMO / ESC=back

Version: 03.00 A

07.04.3.1

CELL NOMINAL LOAD (QN):


- according to type plate of load cell

K15. CELL-FILLING INDICATION SYSTEM:


2000

5-6

- Example of entry for 2000:

daN = CELL-nominal load (Qn)

and continue with

MIN-signal-CELL in mA:
- Output signal of CELL without load
- according to type plate of load cell
- Example of entry for 4.0:
4.00

mA = Q/I-signal (MIN/no load)

and continue with

MAX-signal-CELL in mA:
- Output signal of CELL with nominal load
- according to type plate of load cell
- Example of entry for 20.0:
20.00

mA = Q/I-signal (MAX/at Qn)

and continue with

INFO

The entry procedure for the CELL


ENTRY is now completed:

The entered data must be saved.

and DATA

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
6-6

07.04.3.1

070431-B.doc

Version: 03.00 A

DOSING CONTROL

... SAVING ENTERED DATA


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

MEMO and:

MEMORY = YES:

The new values are saved

10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
CELL-DATA ENTRY
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY

F3

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

MEMORY
= YES

F1

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup procedure for the CELL-DATA ENTRY is


now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL
070432-B.doc

Version: 03.00 B

1-6

CELL-mA-SIGNAL

07.04.3.2

In the Pro Dos DPC setup mode for CELL-mASIGNAL, the signal thresholds of the WESTOMAT
filling level detection system with load cell (CELL) must
be entered:

mA-value of CELL without FURNACE LOAD:


- zero point signal of CELL
- used for subsequent testing of the CELL status

mA-value of CELL with FURNACE LOAD without melt:


- used for subsequent testing of the furnace weight

mA-value of CELL with FURNACE LOAD and min.


operating level = FURNACE EMPTY:
- used for indication and monitoring of the furnace
filling level FURNACE EMPTY

mA-value of CELL with FURNACE LOAD and max.


operating level = FURNACE FULL:
- used for indication and monitoring of the furnace
filling level FURNACE FULL

The setup date of the CELL-mA-SIGNAL is entered


automatically in the LOG K 16.

ATTENTION
This setup procedure may only be carried out on
the fully installed furnace and when the furnace is
at operating temperature. Only melt at operating
temperature may be refilled.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key

F2

= SETUP

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

CELL-mA-SIGNAL
07.04.3.2

2-6

070432-B.doc

The display changes to the general SETUP MODE:

Version: 03.00 B

SETUP MODE:

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

LOG
DATA

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

Select - FILL LEVEL INDICATION by pressing


multi-function key F 2 .

DOSING CONTROL

F1

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

CELL-mA-SIGNAL
070432-B.doc

Version: 03.00 B

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system

3-6

07.04.3.2

... The display changes to selection mode.

Select - CELL SYSTEM by pressing

F4 = DISPLAY MODE of lamps


F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

SETUP MODE:
CELL-FILLING-INDICA

F4

F5

multi-function key

10.03.00
13:34:51
SCAN=CELL

... The display changes to selection mode.

F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup

F2 .

Select - CELL-mA-SIGNAL by pressing

F4 = P/t-MIN MEASURING : when furn. full:


P-pressure, t-time = measure/save
F5 = SIGNAL-CORRECT. - setup correction
due to signal modification
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
mAMEASUR. SIGNAL
SIGNAL

F1

F2

SETUP MODE:
CELL-mA-SIGNAL

F3

F4

F5

10.03.00
13:34:58

SCAN=CELL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL

multi-function key

... The display changes to setup mode.


and shows the following values:

CURRENT MEASURED VALUE - corresponds


to the actual measured value of the mA-signal
of the CELL (with furnace load)

ZERO POINT - corresponds to the status of the


previous setup

FURNACE WITHOUT MELT - corresponds to


the status of the previous setup

13.187 mA = CURRENT VALUE


4.014
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

F3 .

ATTENTION
If the CELL filling level detection system has been
corrected subsequently by means of setup
procedure F5 = SIGNAL-CORRECTION (see
chapter 07.04.3.4), this line shows ****** instead of
the mA-value.

FURNACE EMPTY - corresponds to the status


of the previous setup

FURNACE FULL - corresponds to the status of


the previous setup

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

CELL-mA-SIGNAL
07.04.3.2

4-6

070432-B.doc

SETUP

ZERO POINT:
- mA-signal of CELL without furnace load
- standard value = 4 mA

IMPORTANT NOTES
- The furnace must be fully installed, lifted to
operating height, empty and at operating
temperature
- The CELL is loaded with furnace weight
- The measuring of the mA-signal is
activated, e.g.: CURRENT MEASURED
VALUE = 13.187
- In the event of fluctuations of the mA-signal
by more than 20%, inspect the analog signal
line and especially the shielding for defects
and rectify, if necessary.
- The cursor is placed in the ZERO POINT
line
- Take load off CELL by means of the
support screw at the frame (visible gap
between CELL and furnace base)
- CURRENT MEASURED VALUE = (e.g.)
4.083 corresponds to ZERO POINT SIGNAL
of CELL.

Version: 03.00 B

DOSING CONTROL

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
4.083 mA = CURRENT VALUE
4.014
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
4.083 mA = CURRENT VALUE
4.083
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

Transfer this signal value for ZERO POINT


by pressing
key
The setup automatically continues with line
FURNACE WITHOUT MELT

FURNACE WITHOUT MELT:


- mA-signal of CELL with furnace load and
without melt
- recommended value = see table page 6

IMPORTANT NOTES
- The setup for the mA-value for the CELL
ZERO POINT is now completed.
- The cursor is placed in the line for
FURNACE WITHOUT MELT
- Place furnace load back onto cell by
screwing back the support screw (minimum
distance from screw end to furnace base =
approx. 5 mm)
- the furnace is not supported and carries no
weight and the cleaning door is closed
- The measuring of the mA-signal is
activated, e.g.: CURRENT MEASURED
VALUE = 13.187

Transfer this signal value for FURNACE


WITHOUT MELT by pressing
key
The setup automatically continues with line
OPERATING LEVEL EMPTY.

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
13.187 mA = CURRENT VALUE
4.083
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
13.187 mA = CURRENT VALUE
4.083
13.187
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

CELL-mA-SIGNAL
070432-B.doc

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
14.075 mA = CURRENT VALUE
4.083
13.187
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

Version: 03.00 B

- mA-signal of CELL with furnace load and


minimum operating level of melt = EMPTY
- recommended value = see table

- The cursor is placed in the OPERATING


LEVEL EMPTY line
- Carefully open cleaning door of furnace by
observing
all
safety
instructions
for
protection against aluminium spilling. Refill
furnace via refill funnel until the end of the
dosing pipe and the filling pipe are covered
(by approx. 2 cm).
- the furnace is not supported and carries no
additional weight and the cleaning door is
closed

14.075 mA = CURRENT VALUE


=
=
=
=

IMPORTANT NOTES
- The setup for the mA-value for the CELL
ZERO POINT and FURNACE WITHOUT
MELT is now completed.

zero-point
furnace without melt
operating level EMPTY
operating level FULL

K16. CELL-mA-SIGNAL
mA
mA
mA
mA

07.04.3.2

OPERATING LEVEL EMPTY

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back

4.083
13.187
14.075
11.014
INFO

5-6

zero-point
furnace without melt
operating level EMPTY
operating level FULL

- The measuring of the mA-signal is


activated, e.g.: CURRENT MEASURED
VALUE = 14.075
Transfer this signal value for the
switching threshold for OPERATING LEVEL
EMPTY
by
pressing
key

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
16.396 mA = CURRENT VALUE
4.083
13.187
14.075
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

The setup automatically continues with line


OPERATING LEVEL FULL.

OPERATING LEVEL FULL:


- mA-signal of CELL with furnace load and
maximum operating level of melt = FULL
- recommended value = see table

- The cursor is placed in the line for


OPERATING LEVEL FULL
- Carefully open cleaning door of furnace by
observing all safety instructions for the
protection against aluminium spilling. Refill
furnace via refill funnel until the melt reaches
the outlet edge of the cleaning door frame.

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
MEMO = END SETUP / ESC=back

- the furnace is not supported and carries no


additional weight and the cleaning door is
closed

K16. CELL-mA-SIGNAL

- The measuring of the mA-signal is


activated, e.g.: CURRENT MEASURED
VALUE = 16.396

16.396 mA = CURRENT VALUE


4.083
13.187
14.075
16.396
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

IMPORTANT NOTES

Transfer this signal value for the switching


threshold for OPERATING LEVEL FULL by
pressing
key
of set values.

and continue with saving

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

CELL-mA-SIGNAL
6-6

07.04.3.2

070432-B.doc

Version: 03.00 B

DOSING CONTROL

RECOMMENDED VALUES for mA-signal of CELL


with various loads:
WESTOMAT MODEL
450

650

900

1200

1700

2300

3100

with FURNACE and without MELT

with FURNACE and with MIN. OPERATING LEVEL


EMPTY

with FURNACE and with MAX. OPERATING LEVEL


FULL

... SAVING CELL-mA-SIGNAL


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key MEMO and:

F1

The new values are saved

F3

MEMORY = YES:

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
CELL-mA-SIGNAL
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

MEMORY
= NO

BACK TO
ENTRY

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup of the CELL -mA-SIGNAL is now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL
070433-B.doc

Version: 03.00 B

1 - 10

CELL - P/t-MIN MEASURING

07.04.3.3

The following parameters are set up and saved in the


Pro Dos DPC setup mode for CELL-P/t-MINMEASURING:

P-DC-MIN = MINIMUM FURNACE PRESSURE (in


mbar) at (DC) dosing contact and t-DC = MINIMUM
TIME (in sec) from PRESSURE START to DC:
- when PRESSURE START is
pressure-free furnace chamber

realized

from

P-DC/TS-MIN = MINIMUM FURNACE PRESSURE (in


mbar) and t-DC/TS-MIN = MINIMUM PROCESSING
TIME (in sec) at DC:
- when PRESSURE START is realized from TOPSTOP PRESSURE (i.e. P-TS-HOLD) in the furnace
chamber.

R-DOS-MAX = MAX PRESSURE RAMP after DC:


- Dosing contact DC activates the prop. valve and
the dosing pressure is realized (P-FD in mbar).
Subsequently, the furnace chamber is deaerated.
- The maximum pressure ramp after DC is
measured and displayed, and the optimum values
for dosing (R-DOS in mbar/sec) is calculated based
on this value.

These setup parameters also apply for HPDE filling


level indication.

PROGRAMME CHART of FP/t-MIN-MEASURING

P (mbar)
R -DOS-MAX
P-FD-MAX
P-DC-MIN

DC -1

DK -3

DC -2

P-DC/TS-MIN
P-TS-HOLD

R -DC/TS

R -DC

t (sec)

t -DC/TS-MIN
t -DC-MIN

B
A

A = Programme START

B = METAL FEED

C = Programme END

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.3.3

2 - 10

070433-B.doc

Version: 03.00 B

DOSING CONTROL

The setup for P/t-MIN-MEASURING is carried out by


means of the respective PROCESS PROGRAM. This
programme can be started by pressing the multifunction key F5 in connection with the following DCMDIE signals (from connected DCM):

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


DIE CLOSED ....................................... I-20 / I-21
DIE READY FOR INJECTION ............... I-22 / I-23
PLUNGER IN BACK POSITION ............ I-24

The individual P/t-MIN-MEASURING data and the


setup date are automatically entered in LOG K 17 for
dosing pipe no. 1 and in LOG K 18 for dosing pipe no.
2.

ATTENTION
Any subsequent modifications of the following LOG
data:

K 06 - MAX-FEED PRESSURE (after DC)

K 08 - PRESSURE RAMP DC and DC/TS

K 09 or 10 - INNER DIAMETER / NOZZLE SIZE.


makes the setup values for P/t-MIN-MEASURING
invalid or not suitable for dosing process. The setup
must therefore be repeated.

SCANNING POSITION OF ELECTRODE


INSTRUCTIONS for SETUP of - P/t-MIN-MEAS:

The process programme is to be carried out with


FURNACE FULL, melt at operating temperature
and under the following conditions:

Manual regulator of WESTOMAT pneumatic


unit set to 5 bar

Pressure air line to WESTOMAT pneumatic


unit not contaminated with oil and fully dry,
nominal diameter throttle-free, feed pressure
of min. 5.5 bar

DC test carried out

WESTOMAT and associated assemblies


(pneumatic unit, dosing pipe, refill device, DC
scanning, supply channel) in perfect working
order

Cover of refill funnel closed

15 mm

If DC with electrode, the electrode must be


placed as follows for scanning:
- Position and secure electrode at outlet level
dosing pipe edge
- Measure length of electrode from swivel arm
sensor tip
- Remove electrode and place and secure
such a manner, that the above length
increased by 15 mm

of

to
in
is

A = Sensing electrode

B = Ceramic mantle of dosing pipe

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

P/t-MIN-MEASURING
070433-B.doc

Version: 03.00 B

3 - 10

07.04.3.3

ATTENTION (continued)

Set connected DCM to position MANUAL

Prior to starting the process programme,


remove all aluminium residue from dosing pipe,
the DC device, the outlet channel and the filling
shot sleeve

Closely
observe
progress
of
process
programme and activate EMERGENCY-OFF
switch, if necessary:

at first DC (P-DC-MIN), no metal is fed

at second DC (P -DC-2), no metal is fed

at third DC (P-DC/TS-MIN) and until the feed


pressure is reached, metal is fed. The metal
volumes should be as follows:
- for 40-mm dosing pipes ....up to ca. 1 kg
- for 40-mm dosing pipe .. up to ca. 1.5 kg
- for 65-mm dosing pipe .. up to ca. 1.8 kg
- for 80-mm dosing pipes . up to ca 2.5 kg
- for 100-mm dosing pipes ..up to ca. 5 kg

After END of process program, wait until the


dosed volume has solidified and with the
plunger carefully push hot metal cast from open
DCM die.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 65/21mm 13:34:57
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.3.3

4 - 10

070433-B.doc

The display changes to the general SETUP MODE:

Version: 03.00 B

SETUP MODE:

10.03.00
13:34:57

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

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

Select - FILL LEVEL INDICATION by pressing


LOG
DATA

multi-function key F 2 .

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

DOSING CONTROL

F1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

SETUP MODE:
CELL-FILLING-INDICA

10.03.00
13:34:57

SCAN=CELL
ATTENTION: OPER. INSTRUC. / ESC = back

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT ProDos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
070433-B.doc

DOSING CONTROL

Version: 03.00 B

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system

5 - 10

07.04.3.3

The display changes to selection mode.

C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

F4 = DISPLAY MODE of lamps


F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

Select - CELL SYSTEM by pressing


multi-function key

F1

F2

F3

F4

F2 .

F5
The display changes to selection mode.

SETUP MODE:
CELL-FILLING-INDICA

10.03.00
13:34:51
SCAN=CELL

F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup

DATA ENTRY
CELL-mA-SIGNAL
P/t-MIN-MEASURING
SIGNAL COMPENSATION

F4 = P/t-MIN MEASURING : when furn. full:


P-pressure, t-time = measure/save
F5 = SIGNAL-CORRECT. - setup correction
due to signal modification
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
MaMEASUR. SIGNAL
SIGNAL

F1

F2

F3

F4

F5

Activate P/t-MIN-MEASURING by pressing


multi-function key

F4 .

If two different dosing pipes have been


entered in the LOG, the respective dosing
pipe must be selected here.

Press

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:35
= PIPE SELECTION, ENTER / ESC=back
DOSING PIPE SELECTION
65 /21 mm NO 1 = DOSING PIPE
80 /24 mm NO 2 = DOSING PIPE

or
pipe line
10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:34
= PIPE SELECTION, ENTER / ESC=back
DOSING PIPE SELECTION
65 /21 mm NO 1 = DOSING PIPE
80 /24 mm NO 2 = DOSING PIPE

to place cursor in dosing

and press key


The display changes to the setup mode for
P/t-MIN-MEASURING

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.3.3

6 - 10

070433-B.doc

Version: 03.00 B

If only one dosing pipe has been entered in the


LOG, continue directly to setup mode for P/tMIN-MEASURING:
The display shows the previously set values.
Continue
as
OPERATION ON

described

for

DOSING

DOSING CONTROL

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:34
EXT-KEY DOS-ON or F5 /ESC=back
K17. P/t-MIN
10.03.00
=
16.396 mA =
34.00 (Vp) =
27.58 mbar =
1.87
s =
21.51 mbar =
1.35
s =

- 65/21=DOSIING PIPE NO 1:
setup date
CELL at P/t-MIN-MEASURE
Pres. ramp after DC (mbar/s)
P-DC-MIN-pressure
t-DC-MIN-time
P-DC/TS-MIN-pressure
t-DC/TS-MIN-time

INFO

DOSING
Press key

F 5 = DOSING

F1
... The display changes to query status
establishing whether the WESTOMAT and the
DCM are ready for injection:
- In the above example, no error occurred and
only the plunger, according to the operating
instructions, must be moved back and forth

F2

F3

F4

F5

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:35
Position error: I-24 = 1 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM)

= 1

- PLUNGER was not moved:


- move PLUNGER compl. in FRONT- and
BACK into END POSITION!

DOSING

DCM plunger is moved out

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:35
Position error: I-24 = 0 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM)

No position error occurred. Close DCM DIE


in switch position MANUAL according to
operating instruction.

= 0

- PLUNGER not in END POSITION:


- move PLUNGER completely BACK into
BACK POSITION !

EXT-KEY DOS-ON /instruction/ ESC=back


Instruction for MANUAL DOSING:

The DCM die closes in position MANUAL.

- CLOSE DCM-DIE in position MANUAL


completely !

EXT-KEY DOS-ON /instruction/ ESC=back


To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
- DCM-DIE to be closed in
MANUAL POSITION!

DOSING

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT ProDos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
070433-B.doc

DOSING CONTROL

Version: 03.00 B

7 - 10

07.04.3.3

10.03.00
HEATING
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:35
EXT-KEY DOS-ON /instruction/ ESC=back
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

The DCM die is further closed in position


MANUAL

The DCM die is fully closed in position


MANUAL = ready for injection.

EXT-KEY DOS-ON /instruction/ ESC=back


To DOSING by HAND:

- Press external key DOS-Onto activate


WESTOMAT status ready for injection

DCM-DIE = READY FOR DOSING!

DOSING

MANUAL
SETUP MODE:
DOSING
CELL: P/t-MIN-MEAS. SCAN=CELL
... ON
DOS-by-HAND or F5/DOS-OFF=back
t6

After the external key DOS-ON has been


activated, start P/t-MIN-MEASURING by
pressing the multi-function key F 5 .

Key F 5 is pressed and P/t-MIN-

t7

DCM-DIE
TS=

DC
t2

t3

t4

p = 0.08
INFO

F1

t5

SETUP
START !

F2

F3

F4

F5

MANUAL
SETUP MODE:
DOSING
CELL: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

MEASURING process is started:

t7

DCM-DIE
TS=

t2

p =

t3

t4

after DC-1 (P-DC-MIN) is realized, the


measured value for P-DC-MIN is displayed for
a short moment and the pressure in the
furnace chamber is released - followed by

t5

t7

DCM-DIE
TS=

DC

t2

p =

first pressure rise to DC-1 (P-DC-MIN) started

2.75

Taster DOS von HAND oder F5 = DOSIEREN


t6

DC

t3

t4

t5

28.74
DOSING
by HAND

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.3.3

8 - 10

070433-B.doc

Version: 03.00 B

DOSING CONTROL

MANUAL
SETUP MODE:
DOSING
CELL: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

lag time after furnace pressure release followed by

t7

DCM-DIE
TS=

DC

t2

p =

t3

t4

t5

8.29

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE

second pressure rise to DC -2 (P-DC-2) started

TS=

DC

t2

p =

t3

t4

t5

12.37

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE
after DC-2 (P-DC-2) is realized, the pressure
in the furnace chamber is released - followed
by

TS=

DC

t2

p =

t3

t4

t5

21.87

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE
lag time after pressure release and pressure
rise to TOP-STOP-HOLD

TS=

DC

t2

p =

t3

t4

t5

7.59

Taster DOS von HAND oder F5 = DOSIEREN

furnace chamber pressure for TOP-STOP HOLD is reached (oval display dark) followed
by lag time

t6

t7

DCM-DIE
TS=

DC

t2

p =

third pressure rise to DC-3 (P-DC/TS-MIN)


started

t3

t4

t5

11.87

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE
TS=

DC

t2

p =

t3

t4

t5

18.75
DOSIERENv
on HAND

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT ProDos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
070433-B.doc

DOSING CONTROL

Version: 03.00 B

9 - 10

07.04.3.3

MANUAL
SETUP MODE:
DOSING
CELL: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

t7

DCM-DIE
TS=

DC-3 (P-DC/TS-MIN) is realized and the

DC

t2

t3

t4

p = 21.51
INFO

MANUAL
SETUP
SCAN=CELL
... END

DCM-DIE
TS=

DC

t2

MAX-FEED
PRESSURE
(P-FD-MAX)
is
reached. The programme is completed and
the furnace chamber is deaerated. The
METAL FEED is switched off and the display
shows instructions regarding the activating
of the external key DOS-OFF as well as the
following data:
- pressure ramp R-DOS-MAX (VP )
- pressure P-DC/TS-MIN
- time t -DC/TS-MIN

After pressing of external key DOS-OFF, the


operating instruction is displayed.
- after the cast in the DCM shot sleeve has
solidified,
- remove the (hot) cast by means of the DCM
plunger from the sleeve

Press key

Px=21.51
tx=1.35
Vp=42.57

t7

p =

t5

DOSING
by HAND

SETUP MODE:
CELL: P/t-MIN-MEAS.
USE = KEY DOS-OFF
t6

programme switches to pressure rise to


MAX-FEED
PRESSURE
(P-FD-MAX)
followed by METAL FEED !!!

t3

t4

t5

81.51
DOSING
by HAND

10.03.00
SETUP MODE:
CELL: P/t-MIN-MEAS. 13:34:35
ENTER = continue

HEATING
SCAN=CELL

K21.REFERENCE-kg-DIAGR.65/21mm=NO 1:
OPERATING INSTRUCTION:
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
DOSING

10.03.00
SETUP MODE:
SCAN=CELL
CELL: P/t-MIN-MEAS. 13:34:58
EXT-KEY DOS-ON or F5 /ESC=back
K17.P/t-MIN - 65/21 = DOSING PIPE NO 1:
10.03.00
16.396 mA
34.00 (Vp)
27.58 mbar
1.87
s
21.51 mbar
1.35
s

=
=
=
=
=
=
=

setup date
CELL at P/t-MIN-MEASURE
Pres.ramp after DC (mbar/s)
P-DC-MIN-pressure
t-DC-MIN-time
P-DC/TS-MIN-pressure
t-DC/TS-MIN-time

INFO
DOSING

F1

F2

F3

F4

F5

The individual data is displayed:


- the LED of the MEMO key is blinking (ready
to save):

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
10 - 10

07.04.3.3

070433-B.doc

Version: 03.00 B

DOSING CONTROL

ATTENTION

Check measured values for plausibility:


- For pressure increase after DC: values
between 30 and 40 mbar/sec
- P-DC-MIN > P-DC/TS-MIN (for furnace chamber
pressure at DC), a with difference of
between 5 and 10 mbar
- The CELL-mA-signals must correspond to
signal at FURNACE FULL

It is recommended to
measured values and
procedure:

write done
to repeat

the
the

- Press multi-function key F5 or external key


DOS-ON

and compare new measured values with the


previously measured ones. To save P/t-MINMEASURING data, proceed as follows:

... SAVING P/t-MIN-MEASURING DATA


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

MEMORY = YES:

F1 - SAVE DATA MODIFICATION


F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

The setup
completed.

F5 - BACK TO ENTRY
MEMORY
= YES

MEMORY
= NO

BACK TO
ENTRY

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.
of

10.03.00
13:34:54

SCAN=CELL
ATTENTION: DATA HAVE BEEN MODIFIED!

The new values are saved

F3

SETUP MODE:
CELL: P/t-MIN-MEAS.

MEMO and:

the

P/t-MIN-MEASURING

is

now

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL
070434-B.doc

Version: 03.00 B

1-6

SIGNAL COMPENSATION

07.04.3.4

By means of the Pro Dos DPC setup option for (mA)


SIGNAL COMPENSATION, it is possible to
subsequently correct the signal limit values for the
filling level indication with load cell (CELL).
This correction should be used if the indicated filling
level does not correspond to the actual filling level.
Such deviations might for example be caused by
alterations in the design of the WESTOMAT that
have an impact on the total weight of the unit (load
weight of furnace on CELL).
This SIGNAL CORRECTION only adjusts the limit
values of the following signals:

mA-value of CELL without FURNACE LOAD:


- zero point signal of CELL
- used for subsequent testing of the CELL status

mA-value of CELL with FURNACE LOAD and max.


operating level = FURNACE FULL:
- used for indication and monitoring of the furnace
filling level FURNACE FULL

The signal level of:

mA-value of CELL with FURNACE LOAD without melt:


- used for subsequent testing of the furnace weight

is not measured and the display shows ******.The


signal level of:

mA-value of CELL with FURNACE LOAD and min.


operating level = FURNACE EMPTY:
- used for indication and monitoring of the furnace
filling level FURNACE EMPTY

is calculated from the previous signal difference


between EMPTY and FULL and saved.
The setup date of the CELL-mA-SIGNAL is entered
automatically in the LOG K 16.

SETUP PROCEDURE
Prior to carrying out of SIGNAL COMPENSATION,
inspect furnace and CELL signal status as follows:

Prepare furnace for test:

install and lift to operating height

Fill up to max. filling level FURNACE FULL (melt


level with outlet edge of cleaning door):
- Filling must be carried out via funnel and
under supervision and the cleaning door must
be open
- Comply with all safety measures to prevent
splashing of aluminium
- At FURNACE FULL, close cleaning door
(airtight)

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SIGNAL COMPENSATION
2-6

07.04.3.4

070434-B.doc

Version: 03.00 B

Check CELL-signal:

Access

DOSING CONTROL

OFFLINE:
27.65kg
MANUAL
DOSING
SCAN=CELL ... ON
DOS. PIPE: 100/35mm
ESC=back

I / O LEVEL and press F 3

to display current CELL-signals. Write down


displayed mA-values.

ANALOG INPUT AND OUTPUT


Measuring pressure converter: 6.893 mA
Load cell:
15.695 mA
Thermocouple melt:
698 C
Thermocouple furnace chamber:
738 C
controll. output prop. valve
1.452 V
SERVICE ANALOG
DIGITAL SIGNALS
IN
IN / OUT WO-DCM

Access

DATA DISPLAY and press

F5

to activate SETUP DATA and


press
visible.

= DATA LOG

until K 16. CELL-mA-SIGNAL is

AUTO
DOSING
SCAN=CELL ... END
/

ESC=back

K16. CELL-mA-SIGNAL:

Compare saved mA-value for OPERATING


LEVEL FULL with current mA-value

OFFLINE:
10.65kg
DOS. PIPE: 80/24 mm

Deviations of more than 0.1 mA are not


permitted. In such a case, the subsequent
correction (SIGNAL COMPENSATION) for the
CELL filling level indication is required.

ATTENTION

= CELL ACTIVE
12.07.99
= setup date
4.087
mA = Zero point (CELL without
load)
10.883 mA = at furnace without melt
13.267 mA = (MIN) operating level empty
16.359 mA = (MAX) operating level full
FILL
LDTCYCLE
SETUP
LEVEL
SETUP
DATA
DATA

- In the event of fluctuations of the mA-signal by more


than 20%, inspect the analog signal line and especially
the shielding for defects and rectify, if necessary.

Activate CELL - SIGNAL CORRECTION:


- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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

multi-function key

F 2 = SETUP

P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

SIGNAL COMPENSATION
070434-B.doc

DOSING CONTROL

SETUP MODE:

SETUP MODE
FILLING LEVEL INDICATION / CELL
Version: 03.00 B

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

F1

=
=
=
=
=

F3

F4

The display changes to the general SETUP MODE:


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

1
1
1
1
1

F5

07.04.3.4

The visualisation field shows the currently saved

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

3-6

Select - FILL LEVEL INDICATION by pressing


multi-function key

F2 .

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back

F2

The display form with instructions for entry of


the code number appears

- THIS SETUP PROCEDURE MAY ONLY BE


PERFORMED BY AUTHORISED PERSONNEL

Enter code number and press


The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

press multi-function key

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears


10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

Press
The SETUP MODE for the CELL FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SIGNAL COMPENSATION
07.04.3.4

4-6

070434-B.doc

... The display changes to selection mode.

Select - CELL SYSTEM by pressing

Version: 03.00 B

DOSING CONTROL

10.03.00
13:34:51
SCAN=CELL
CELL-FILLINGINDICATION
F = MENU / ESC=back
F2 = CELL-SYSTEM / load cell as
filling level detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

multi-function key

F2 .

F1

F2

F3

F4

F5

... The display changes to selection mode.

Select SIGNAL COMPENSATION by pressing

10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDICA 13:34:51
F = MENU / ESC=back
F2 = DATA ENTRY for CELL-system
F3 = CELL-mA-SIGNAL - setup
F4 = P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save

multi-function key

F5 .

... The display changes to setup mode and the


measuring is carried out. The following values are
displayed:

CURRENT MEASURED VALUE - corresponds


to the current signal value of the CELL at load
with max. operating level FURNACE FULL
(furnace not further supported or loaded)

Compare measured value with the saved


(previous) value for max. operating level
FURNACE FULL

ZERO POINT - corresponds to the value of the


previous setup

FURNACE WITHOUT MELT - corresponds to


the value of the previous setup
If the CELL filling level detection system has
been corrected subsequently by means of setup
procedure F5 = SIGNAL-CORRECTION, this
line shows ****** instead of the mA-value.

FURNACE EMPTY - corresponds to the value of


the previous setup

FURNACE FULL - corresponds to the value of


the previous setup

F5 = SIGNAL-CORRECT. - setup correction


due to signal modification
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
mAMEASUR. SIGNAL
SIGNAL

F1

F2

F3

F4

F5

10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
SIGNAL COMPENSATION
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
16.396 mA = CURRENT VALUE
4.054
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / CELL

SIGNAL COMPENSATION
070434-B.doc

10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL
4.083 mA = CURRENT VALUE
4.054
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

Version: 03.00 B

5-6

07.04.3.4

SETUP

ZERO POINT:
- mA-signal of CELL without furnace load
- standard value = 4 mA

IMPORTANT NOTES
- Take load off CELL by means of support
screws at the frame (visible distance
between CELL and furnace base)

zero-point
furnace without melt
operating level EMPTY
operating level FULL

The measuring of the mA-signal is


activated, e.g.: CURRENT MEASURED
VALUE = 4.083

- The cursor is placed in the ZERO POINT


line
10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back

- In the event of fluctuations of the mA-signal


by more than 20%, inspect the analog
signal line and especially the shielding for
defects and rectify, if necessary.

K16. CELL-mA-SIGNAL
4.083 mA = CURRENT VALUE
4.083
6.014
8.014
11.014
INFO

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

The cursor is automatically set to line


operating level

10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
MEAS-ACTIVE,ENTER=TAKE OVER / ESC=back
K16. CELL-mA-SIGNAL

FURNACE FULL:
- mA-signal of CELL with furnace load and
maximum operating level of melt = FULL

16.396 mA = CURRENT VALUE


4.083
13.187
14.075
11.014
INFO

mA
mA
mA
mA

=
=
=
=

IMPORTANT NOTES
- The cursor is placed in the line for
OPERATING LEVEL FULL

zero-point
furnace without melt
operating level EMPTY
operating level FULL

- the furnace is not supported and carries no


weight and the cleaning door is closed
-

10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
MEMO = END SETUP / ESC=back
K16. CELL-mA-SIGNAL
16.396 mA = CURRENT VALUE
4.083
13.187
14.075
16.396
INFO

Transfer this signal value for ZERO POINT


by pressing

mA
mA
mA
mA

=
=
=
=

zero-point
furnace without melt
operating level EMPTY
operating level FULL

The measuring of the mA-signal is


activated, e.g.: CURRENT MEASURED
VALUE = 16.396

Transfer this signal value for the switching


threshold for OPERATING LEVEL FULL by
pressing
key
values.

and continue with saving of set

SETUP MODE
FILLING LEVEL INDICATION / CELL

WESTOMAT P ro Dos DPC


OPERATING MANUAL

SIGNAL COMPENSATION
6-6

07.04.3.4

070434-B.doc

Version: 03.00 B

DOSING CONTROL

... SAVING CELL-mA-SIGNAL


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

MEMO and:

10.03.00
SETUP MODE:
13:34:54 SCAN=CELL
SIGNAL COMPENSATION
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION

F1

MEMORY = YES:

The new values are saved

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY

F3

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup of the CELL-mA-SIGNAL COMPENSATION


is now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION
07044-B.doc

Version: 03.00 B

1-4

HPDE-FILLING LEVEL SYSTEM - GENERAL

07.04.4

Depending on the WESTOMAT equipment, the filling


level scanning system with the hydraulic-pneumatic
pressure detection system (HPDE) is activated in the
Pro Dos DPC LOG K 03.
The initial setup of the filling level scanning system is
carried out at commissioning in the setup for FILL
LEVEL INDICATION. Subsequent modification of the
parameters are equally made in this setup option.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key

F 2 = SETUP

The display changes to the general SETUP MODE:

The visualisation field shows the currently saved

SETUP MODE:

10.03.00
13:34:57
SCAN=HPDE
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

F1

values of the individual setup options:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Select - FILL LEVEL INDICATION by pressing


multi-function key

F2 .

SETUP MODE
FILLING LEVEL INDICATION

HPDE-FILLING LEVEL SYSTEM - GENERAL


07.04.4

07044-B.doc

2-4

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
H P D E SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

Press
The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
H P D E SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
CONTINUE PROCEDURE WITH ENTER

... The display changes to selection mode.

Select - HPDE SYSTEM by pressing

10.03.00
SETUP MODE:
SCAN=CELL
HPDE-FILLING INDICA 13:34:51
F = MENU / ESC=back
F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system
F4 = DISPLAY MODE of lamps

multi-function key

F2 .

F5 = SWITCHING THRESHOLDS: of lamps


standard / accord. to selection
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION

HPDE-FILLING LEVEL SYSTEM - GENERAL


07044-B.doc

10.03.00
SETUP MODE:
HPDE-FILLING INDICA 13:34:51
F = MENU / ESC=back

Version: 03.00 B

... The display changes to selection mode.

The setup procedures for HPDE filling level scanning


must be entered and saved as follows:

F5 = P/t-MIN MEAS: when furn. full:


P-pressure, t-time = measure/save
DATA
ENTRY

P/t-MIN
MEASUR.

in HPDE -DATA ENTRY:

see chapter 07.04.4.1

cycle time for LEVEL-SCANNING

furnace filling level data:

F1

F2

F3

F4

07.04.4

SCAN=HPDE

F4 = DATA ENTRY for HPDE-system

INFO

3-4

F5

kg-values, valid for both HPDE and CELL


system (see chapter 07.04.4.1)

in chapter P/t-MIN-MEASURING:

see chapter 07.04.4.2

measured values for pressure and time at


realization of dosing contact if FURNACE FULL

these parameters apply to both the HPDE


system and the CELL system (see chapter
07.04.3.3)

ATTENTION
If the DATA ENTRY and P/t-MIN-MEASURING
setup for CELL filling level detection for the
WESTOMAT has been completed previously and
according to the equipment of the unit, the
respective data is already saved for HPDE
operation. The entry and setup must be repeated.
The saved data and the setup data are automatically
recorded in LOG K13, K14 and K17 to K19.

ATTENTION
During these setup procedures, the filling level
indication of the furnace is deactivated.
The filling level scanning by means of the HPDE
system is only fully activated if the DOSING
OPERATION is switched on (with operating modes
TOP-STOP and LEVEL-SCANNING).

SETUP MODE
FILLING LEVEL INDICATION

HPDE-FILLING LEVEL SYSTEM - GENERAL


07.04.4

4-4

07044-B.doc

blank page

Version: 03.00 B

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / HPDE
070441-B.DOC

Version: 03.00 B

1-6

DATA ENTRY

07.04.4.1

In the DPC setup option HPDE-DATA ENTRY, the


basic data of the WESTOMAT filling level scanning
with hydraulic-pneumatic pressure detection system
(HPDE) must be entered:

If the WESTOMAT is equipped with a filling level


scanning system with load cell (CELL), the
respective data for SWITCHING THRESHOLDS,
DISPLAY MODE and P/t-MIN-MEASURING is
automatically transferred.

FURNACE OPERATING FILLING LEVEL:


- melt volume available for dosing (in kg, also
applicable for CELL scanning).

REFILL CHARGE:
- when this value is reached (in kg, also applicable
for CELL scanning), the signal (O-04) REFILL
CHARGE is automatically activated.
- For reasons of quality, the refill charge should not
exceed approx. 50 % of the operating filling level
of the furnace.

O-04 REFILL ACKNOWLEDGED:


- when this volume (in kg, also applicable for CELL
scanning) has been refilled, the signal (O-04)
REFILL CHARGE is automatically reset.

CYCLE TIME for LEVEL-SCANNING:


- When refilling the furnace (refill lid OPEN and
after lapse of cycle time), the melt in the dosing
pipe is pumped up to DC (dosing contact).
- The filling level detection is carried out at the
moment of DC and according to the measured
furnace chamber pressure.

The setup date of the HPDE DATA ENTRY is entered


automatically in LOG K 19.

SETUP PROCEDURE
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=HPDE
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

- see also chapter 07.00.


In BASIC STATUS of the Pro Dos DPC, press:

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key

F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
07.04.4.1

070441-B.DOC

2-6

Version: 03.00 B

The display changes to the general SETUP MODE:

SETUP MODE:

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

Select pressing

FILLING

multi-function key

LEVEL

INDICATION

DOSING CONTROL

10.03.00
13:34:57
SCAN=HPDE
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

F2 .

F1

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

=
=
=
=

1
1
1
1

AVAILABLE = 1,040 kg MELT


FILL
LDT
kg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in LOG K 12.
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


BEDIENANLEITUNG

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / HPDE

DATA ENTRY
070441-B.DOC

Version: 03.00 B

3-6

07.04.4.1

... The display changes to selection mode.

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:51
F = MENU / ESC=back

Select - HPDE SYSTEM by pressing

F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system
F4 = DISPLAY MODE of lamps
F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.
multi-function key

F1

F2

F3

F4

F2 .

F5

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:51
F = MENU / ESC=back

... The display changes to selection mode.

Select - DATA ENTRY by pressing

F4 = DATA ENTRY for HPDE-system


F5 = P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save
INFO

DATA
ENTRY

P/t-MIN
MEASUR.
multi-function key F 4 .

F1

F2

F3

F4

F5

... The display changes to entry mode.

DATA ENTRY

kg-FURNACE OPERATING FILLING LEVEL:


10.03.00
SETUP MODE:
13:34:58
SCAN=HPDE
HPDE-DATA ENTRY
, INPUT, ENTER and MEMO / ESC=back
K19. HPDE-FILLING INDICATION SYSTEM:
13.09.99

FURNACE OPERATING FILLING LEVEL of MELT


(in kg) for WESTOMAT model
450

650

900

1200

1700

2300

3100

300

500

700

900

1400

1800

2450

= setup date
- Example of entry for 700:

7
700
INFO

kg = fur.operating filling level

and continue with

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
4-6

07.04.4.1

070441-B.DOC

kg-REFILL CHARGE:

- The kg-value of the REFILL CHARGE depends


on the size of the refilling and transport devices.
- For reasons of quality, the REFILL CHARGE
should not exceed 50% of the OPERATING
FILLING LEVEL in the furnace.

Version: 03.00 B

SETUP MODE:
HPDE-DATA ENTRY

DOSING CONTROL

10.03.00
13:34:58

SCAN=HPD
E

, INPUT, ENTER and MEMO / ESC=back


K19. HPDE-FILLING INDICATION SYSTEM:

- If the furnace is to be emptied, and a filling


level of e.g. 700 300 = 400 kg is reached, O04 = from 0 to 1
- The signal O-04 = 1 REFILL, the complete
refill charge can be filled into the furnace.
- Example of entry for 300:

and continue with

O-04 REFILL ACKNOWLEDGED:

300

kg = refill charge

150

kg = O-04-REFILL ACKNOWLEDGED

- As soon as the furnace is refilled with at least


this volume, e.g. 700 300 + 150 = 550 kg,
signal O-04 = from 1 to 0.
- Example of entry for 150:

and continue with

ATTENTION
Values for:

FURNACE OPERATING FILLING LEVEL:

REFILL CHARGE:

O-04 REFILL ACKNOWLEDGED:

are automatically transferred to CELL FILLING


LEVEL (in LOG K 15).

INFO

DIAGRAM OF FURNACE FILLING LEVELS

B O-04 = 0 = kg
A O-04 = 1 = kg

MAX-AL = kg
O-17 = 100%
O-18 = 92%
O-19 = 69%
O-20 = 46%
O-21 = 23%
= 0%

O-04

1
0

MAX-AL = FURN. OPERAT. FILLING LEVEL


A
= REFILL CHARGE
B
= O-04-REFILL ACKNOWLEDGED

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT ProDos DPC


BEDIENANLEITUNG

DATA ENTRY
070441-B.DOC

DOSING CONTROL

10.03.00
13:34:58

SETUP MODE:
HPDE-DATA ENTRY

Version: 03.00 B

SCAN=HPD
E

5-6

07.04.4.1

LEVEL-SCANNING - cycle time:


- After refill and activated LEVEL-SCANNING,
the scan procedure (lifting of melt to dosing
contact) is carried out in cycles after this time
has lapsed

, INPUT, ENTER and MEMO / ESC=back


K19. HPDE-FILLING INDICATION SYSTEM:

- STANDARD value = 10 sec


- Min. value = 5 sec
- Max. value = 15 sec
- Example of entry for 10:
10

s = Cycle for LEVEL-SCANNING

INFO

and continue with

The entry procedure for


ENTRY is now completed:

the

HPDE-DATA

The entered data must be saved.

... SAVING ENTERED DATA


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key


10.03.00
13:34:54

SETUP MODE:
HPDE-DATA ENTRY

SCAN=HPD
E

F1

MEMO and:

MEMORY = YES:

The new values are saved

ATTENTION: DATA HAVE BEEN MODIFIED!

F1 - SAVE DATA MODIFICATION

F3

F3 DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5 - BACK TO ENTRY
MEMO
= YES

F1

MEMO =
NO

F2

F3

BACK TO
ENTRY

F4

F5

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup procedure for the HPDE-DATA ENTRY is


now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

DATA ENTRY
07.04.4.1

6-6

070441-B.DOC

blank page

Version: 03.00 B

DOSING CONTROL

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / HPDE
070442-B.doc

Version: 03.00 B

1 - 10

HPDE - P/t-MIN-MEASURING

07.04.4.2

The following parameters are set up and saved in the


Pro Dos DPC setup mode for HPDE-P/t-MINMEASURING:

P-DC-MIN = MINIMUM FURNACE PRESSURE (in


mbar) at (DC) dosing contact and t-DC-MIN =
MINIMUM TIME (in sec) from PRESSURE START
to DC:
- when PRESSURE START is
pressure-free furnace chamber

realized

from

P-DC/TS-MIN = MINIMUM FURNACE PRESSURE (in


mbar) and t-DC/TS-MIN = MINIMUM PROCESSING
TIME (in sec) at DC:
- when PRESSURE START is realized from TOPSTOP PRESSURE (i.e. P-TS-HOLD) in the furnace
chamber.

R-DOS-MAX = MAX PRESSURE RAMP after DC:


- Dosing contact DC activates the prop. valve and
the dosing pressure is realized (P-FD in mbar).
Subsequently, the furnace chamber is deaerated.
- The maximum pressure ramp after DC is
measured and displayed, and the optimum values
for dosing (R-DOS in mbar/sec) is calculated
based on this value.

These setup parameters also apply for CELL filling


level indication.

PROGRAMME CHART of P/t-MIN-MEASURING

P (mbar)
R -DOS-MAX
P-FD-MAX
P-DC-MIN

DC -1

DK -3

DC -2

P-DC/TS-MIN
P-TS-HOLD

R -DC/TS

R -DC

t (sec)

t -DC/TS-MIN
t -DK-MIN

B
A

A = Programme START

B = METAL FEED

C = Programme END

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.4.2

2 - 10

070442-B.doc

Version: 03.00 B

DOSING CONTROL

The setup for P/t-MIN-MEASURING is carried out by


means of the respective PROCESS PROGRAM. This
programme can be started by pressing the multifunction key F5 in connection with the following DCMDIE signals (from connected DCM):

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


DIE CLOSED .................................. I-20 / I-21
DIE READY FOR INJECTION .......... I-22 / I-23
PLUNGER IN BACK POSITION ................ I-24

The individual P/t-MIN-MEASURING data and the


setup date are automatically entered in LOG K 17 for
dosing pipe no. 1 and in LOG k18 for dosing pipe no.
2.

ATTENTION
Any subsequent modifications of the following LOG
data:

K 06 - MAX-FEED PRESSURE (after DC)

K 08 - PRESSURE RAMP DC and DC/TS

K 09 or 10 - INNER DIAMETER / NOZZLE SIZE.


makes the setup values for P/t-MIN-MEASURING
invalid or not suitable for dosing process. The setup
must therefore be repeated.

SCANNING POSITION OF ELECTRODE


INSTRUCTIONS for SETUP of - P/t-MIN-MEAS:

The process programme is to be carried out with


FURNACE FULL, melt at operating temperature
and under the following conditions:

Manual regulator of WESTOMAT pneumatic


unit set to 5 bar

Pressure air line to WESTOMAT pneumatic


unit not contaminated with oil and fully dry,
nominal diameter throttle-free, feed pressure
of min. 5.5 bar

DC test carried out

The WESTOMAT and associated assemblies


(pneumatic unit, dosing pipe, refill device, DC
scanning, supply channel) must be in perfect
working order.

Cover of refill funnel closed

15 mm

For DC with electrode, the electrode must be


placed as follows for scanning:
- Position and secure electrode at outlet level
dosing pipe edge
- Measure length of electrode from swivel arm
sensor tip
- Remove electrode and place and secure
such a manner, that the above length
increased by 15 mm

of

to
in
is

A = Sensing electrode

B = Ceramic mantle of dosing pipe

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / HPDE

P/t-MIN-MEASURING
070442-B.doc

Version: 03.00 B

3 - 10

07.04.4.2

ATTENTION (continued)

Set connected DCM to position MANUAL

Prior to starting the process programme,


remove all aluminium residue from dosing pipe,
the DC device, the outlet channel and the filling
shot sleeve

Closely
observe
progress
of
process
programme and activate EMERGENCY-OFF
switch, if necessary:

at first DC (P-DC-MIN), no metal is fed

at second DC (P -DC-2), no metal is fed

at third DC (P-DC/TS-MIN) and until the feed


pressure is reached, metal is fed. The metal
volumes should be as follows:
- for 40-mm dosing pipes ....up to ca. 1 kg
- for 50-mm dosing pipe .. up to ca. 1.5 kg
- for 65-mm dosing pipe .. up to ca. 1.8 kg
- for 80-mm dosing pipes ....up to ca. 2.5
kg
- for 100-mm dosing pipes ..up to ca. 5 kg

After END of process program, wait until the


dosed volume has solidified and with the
plunger carefully push hot metal cast from open
DCM die.

SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

multi-function key F 2 = SETUP

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.4.2

070442-B.doc

4 - 10

Version: 03.00 B

The display changes to the general SETUP MODE:

SETUP MODE:

10.03.00
13:34:57

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

Select pressing

FILLING

multi-function key

LEVEL

INDICATION

DOSING CONTROL

SCAN=HPDE
F = MENU / ESC=back
SETUP of OPERATING DATA for:
F1: LOG DATA ......................
F2: FILL LEVEL INDICATION .........
F3: LDT = LANGUAGE/DATE/TIME ......
F4: kg-DIAGRAM ....................
F5: REGULATOR DATA and HEAT-FUNCT..

by
LOG
DATA

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2 .

F1

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL

F2

F3

F4

F5

Access to this SETUP OPTION can be locked by


code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in LOG K 12.
If the SETUP MODE is code-locked,

press multi-function key

F2

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F2

The display form with instructions appears

Press
The SETUP MODE for the HPDE FILLING
LEVEL INDICATION is now accessible and the
display changes to the selection mode for the
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
FILLING LEVEL INDICATION / HPDE

P/t-MIN-MEASURING
070442-B.doc

Version: 03.00 B

10.03.00
SETUP MODE:
SCAN=CELL
HPDE-FILLING INDICA 13:34:51
F = MENU / ESC=back

5 - 10

07.04.4.2

The display changes to selection mode.

F2 = HPDE-SYSTEM / hydraulic-pneumatic
pressure detection as filling level
detection system

HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

F4 = DISPLAY MODE of lamps


F5 = SWITCHING THRESHOLDS: of lamps
standard / accord. to selection
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.

F1

F2

F3

F4

Select - HPDE SYSTEM by pressing


multi-function key

F5

F2 .

The display changes to selection mode.


SETUP MODE:
HPDE-FILLING INDICA

10.03.00
13:34:51

SCAN=HPDE

DATA ENTRY
P/t-MIN-MEAS.

F = MENU / ESC=back
F4 = DATA ENTRY for HPDE-system
F5 = P/t-MIN MEASURING : when furn. full:
P-pressure, t-time = measure/save
INFO

DATA
ENTRY

P/t-MIN
MEASUR.

Activate P/t-MIN-MEASURING by pressing


multi-function key

F1

F2

F3

F4

F5 .

F5

If two different dosing pipes have been


entered in the LOG, the respective dosing
pipe must be selected here.

by pressing

10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:35
= PIPE SELECTION, ENTER / ESC=back
SELECTION DOSING PIPE
65 /21 mm NO 1 = DOSING PIPE
80 /24 mm NO 2 = DOSING PIPE

or
line
10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:34
= PIPE SELECTION, ENTER / ESC=back
SELECTION DOSING PIPE
65 /21 mm NO 1 = DOSING PIPE
80 /24 mm NO 2 = DOSING PIPE

place cursor in dosing pipe

and press key


The display changes to the setup mode for
P/t-MIN-MEASURING

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.4.2

6 - 10

070442-B.doc

Version: 03.00 B

If only one dosing pipe has been entered in the


LOG, continue directly to setup mode for P/tMIN-MEASURING:
The display shows the previously set values.
Continue
as
described
OPERATION ON

for

DOSING

DOSING CONTROL

10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:34
EXT-KEY DOS-ON or F5 /ESC=back
K17. P/t-MIN - 65/1 =DOSING PIPE NO 1:
10.03.00
16.396 mA
34.00 (Vp)
27.58 mbar
1.87
s
21.51 mbar
1.35
s

=
=
=
=
=
=
=

setup date
HPDE at P/t-MIN-MEASURE
Pres. ramp after DC (mbar/s)
P-DC-MIN-pressure
t-DC-MIN-time
P-DC/TS-MIN-pressure
t-DC/TS-MIN-time

INFO

Press key

DOSING

F 5 = DOSING

F1
... The display changes to query status
establishing whether the WESTOMAT and the
DCM are ready for injection:
- In the above example, no error occurred and
only the plunger, according to the operating
instructions, must be moved back and forth

F2

F3

F4

F5

10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:35
Position error: I-24 = 1 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM) .... =
1
- PLUNGER was not moved:
- move PLUNGER compl. in FRONT- and
BACK into END POSITION!

DOSING

DCM plunger is moved out


10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:35
Position error: I-24 = 0 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM) .... =
0

No position error occurred. Close DCM DIE


in switch position MANUAL according to
operating instruction.

- PLUNGER not in END POSITION:


- move PLUNGER compl. in FRONT- and
BACK POSITION !

EXT-KEY DOS-ON /instruction/ ESC=back


Instruction for MANUAL DOSING:

the DCM die is closed in position MANUAL.


- CLOSE DCM-DIE in position MANUAL
completely !

EXT-KEY DOS-ON /instruction/ ESC=back


To DOSING by HAND:
I-19 DIE CLOSES (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

DOSING

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT ProDos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
070442-B.doc

DOSING CONTROL

Version: 03.00 B

7 - 10

07.04.4.2

10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:35
EXT-KEY DOS-ON /instruction/ ESC=back
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

The DCM die is further closed in position


MANUAL

The DCM die is fully closed in position


MANUAL = ready for injection.

EXT-KEY DOS-ON /instruction/ ESC=back


To DOSING by HAND:

- Press external key DOS-Onto activate


WESTOMAT status ready for injection

DCM-DIE = READY FOR DOSING!

DOSING

MANUAL
SETUP MODE:
DOSING
HPDE: P/t-MIN-MEAS. SCAN=CELL
... ON
DOS-by-HAND or F5/DOS-OFF=back
t6

After the external key DOS-ON has been


activated, start P/t-MIN-MEASURING by
pressing the multi-function key F 5 .

Key F 5 is pressed and P/t-MIN-

t7

DCM-DIE
TS=

DC
t2

t3

t4

p = 0.08
INFO

F1

t5

SETUP
START !

F2

F3

F4

F5

MANUAL
SETUP MODE:
DOSING
HPDE: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

MEASURING process is started:

t7

DCM-DIE
TS=

t2

p =

t3

t4

after DC-1 (P-DC-MIN) is realized, the


measured value for P-DC-MIN is displayed for
a short moment and the pressure in the
furnace chamber is released - followed by

t5

t7

DCM-DIE
TS=

DC

t2

p =

first pressure rise to DC-1 (P-DC-MIN) started

2.75

Taster DOS von HAND oder F5 = DOSIEREN


t6

DC

t3

t4

t5

28.74
DOSING
by HAND

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
07.04.4.2

8 - 10

070442-B.doc

Version: 03.00 B

DOSING CONTROL

MANUAL
SETUP MODE:
DOSING
HPDE: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

lag time after furnace pressure release followed by

t7

DCM-DIE
TS=

DC

t2

p =

t3

t4

t5

8.29

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE

second pressure rise to DC -2 (P-DC-2) started

TS=

DC

t2

p =

t3

t4

t5

12.37

Taster DOS von HAND oder F5 = DOSIEREN

t6

after DC-2 (P-DC-2) is realized, the pressure


in the furnace chamber is released - followed
by

t7

DCM-DIE
TS=

DC

t2

p =

t3

t4

t5

21.87

Taster DOS von HAND oder F5 = DOSIEREN

lag time after pressure release and pressure


rise to TOP-STOP-HOLD

t6

t7

DCM-DIE
TS=

DC

t2

p =

furnace chamber pressure for TOP-STOP HOLD is reached (oval display dark) followed
by lag time

t3

t6

t7

DCM-DIE
DC

t2

p =
third pressure rise to DC-3 (P-DC/TS-MIN)
started

t5

Taster DOS von HAND oder F5 = DOSIEREN

TS=

t4

7.59

t3

t4

t5

11.87

Taster DOS von HAND oder F5 = DOSIEREN


t6

t7

DCM-DIE
TS=

DC

t2

p =

t3

t4

t5

18.75
DOSING
by HAND

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT ProDos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
070442-B.doc

DOSING CONTROL

Version: 03.00 B

9 - 10

07.04.4.2

MANUAL
SETUP MODE:
DOSING
HPDE: P/t-MIN-MEAS. SCAN=CELL
... RUN
Taster DOS von HAND oder F5 = DOSIEREN
t6

t7

DCM-DIE
TS=

DC-3 (P-DC/TS-MIN) is realized and the

DC

t2

t3

t4

p = 21.51
INFO

MANUAL
SETUP
SCAN=CELL
... END

DCM-DIE
TS=

DC

t2

MAX-FEED
PRESSURE
(P-FD-MAX)
is
reached. The programme is completed and
the furnace chamber is deaerated. The
METAL FEED is switched off and the display
shows instructions regarding the activating
of the external key DOS-OFF as well as the
following data:
- pressure ramp R-DOS-MAX (VP )
- pressure P-DC/TS-MIN
- time t -DC/TS-MIN

After pressing of external key DOS-OFF, the


operating instruction is displayed.
- after the cast in the DCM shot sleeve has
solidified,
- remove the (hot) cast by means of the DCM
plunger from the sleeve

Press key

Px=21.51
tx=1.35
Vp=42.57

t7

p =

t5

DOSING
by HAND

SETUP MODE:
HPDE: P/t-MIN-MEAS.
USE = KEY DOS-OFF
t6

programme switches to pressure rise to


MAX-FEED
PRESSURE
(P-FD-MAX)
followed by METAL FEED !!!

t3

t4

t5

81.51
DOSING
by HAND

10.03.00
SETUP MODE:
HPDE: P/t-MIN-MEAS. 13:34:35
ENTER = continue

HEATING
SCAN=HPDE

K21. REFERENCE-kg-DIAGR.65/21mm=NO 1:
OPERATING INSTRUCTION:
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !

DOSING

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:58
EXT-KEY DOS-ON or F5 /ESC=back
K17. P/t-MIN - 65/21 =DOSING PIPE NO 1:
10.03.00
= setup date
16.396 mA = HPDE at P/t-MIN-MEASURE
34.00 (Vp) = Pres. ramp after DC (mbar/s)
27.58 mbar = P-DC-MIN-pressure
1.87 s = t-DC-MIN-time
21.51 mbar = P-DC/TS-MIN-pressure
1.35 s = t-DC/TS-MIN-time
INFO
DOSING

F1

F2

F3

F4

F5

The individual data is displayed:


- the LED of the MEMO key is blinking (ready
to save):

SETUP MODE
FILLING LEVEL INDICATION / HPDE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

P/t-MIN-MEASURING
10 - 10

07.04.4.2

070442-B.doc

Version: 03.00 B

DOSING CONTROL

ATTENTION

Check measured values for plausibility:


- For pressure increase after DC: values
between 30 and 40 mbar/sec
- P-DC-MIN > P-DC/TS-MIN (for furnace chamber
pressure at DC), a with difference of
between 5 and 10 mbar

It is recommended to
measured values and
procedure:

write done
to repeat

the
the

- Press multi-function key F5 or external key


DOS-ON

and compare new measured values with the


previously measured ones. To save P/t-MINMEASURING data, proceed as follows:

... SAVING P/t-MIN-MEASURING DATA


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

MEMO and:

MEMORY = YES:

F1 - SAVE DATA MODIFICATION

The new values are saved

F3

10.03.00
SETUP MODE:
SCAN=HPDE
HPDE: P/t-MIN-MEAS. 13:34:54
ATTENTION: DATA HAVE BEEN MODIFIED!

F3 - DO NOT SAVE DATA MODIFICATION


KEEP DATA UNMODIFIED

MEMORY = NO:

F5 - BACK TO ENTRY

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

The setup
completed.

F1

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.
of

the

P/t-MIN-MEASURING

MEMORY
= YES

is

now

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE

0705-B.doc

Version: 03.00 B

1-2

kg-DIAGRAM

07.05

In the kg-DIAGRAM setup option, the data for the


dosing volume range (smallest and largest dosing
volumes) for the WESTOMAT are set up and saved
in the Pro Dos DPC.

EXAMPLES of SETUP DATA


K06. PRESSURE FURNACE CHAMBER:
80
mbar = MAX-feed press. (after P-DC)

The kg-DIAGRAM setup must be carried out prior to


commissioning of the WESTOMAT and only after the
following operating data and setup procedure (SMs) of
the Pro Dos DPC have been completed and saved.
If any of the following parameters are modified at a
later stage, the kg-DIAGRAM must be setup again:

K08. SPEED OF PRESSURE RISE:


15.0
= ramp-DC (in mbar/s)
7.5
= ramp-DOSING (in mbar/s)

SM - LOG DATA:

K 06. PRESSURE FURNACE CHAMBER:


- MAX-FEED PRESSURE

K 08. SPEED OF PRESSURE RISE:


- PRESSURE RAMP-DC
- PRESSURE RAMP-DC/TS/TS

K 09. DOSING PIPE-NO 1


- INNER DIAMETER
- NOZZLE BORE

K 10. DOSING PIPE-NO 2 (if installed)


- INNER DIAMETER
- NOZZLE BORE

K09. DOSING PIPE-NO 1:


65
21
146

mm = inner diameter
mm = nozzle bore
mm = MIN-ris. h.w/h dos. pipe

K10. DOSING PIPE-NO 2:


80
24
141

mm = inner diameter
mm = nozzle bore
mm = MIN-ris. h.w/h dos. pipe

K17. P/t-MIN - 80/24 =DOSING PIPE NO 1:

SM - FILLING LEVEL SCANNING and SM - P/tMIN-MEASURING:

K 17. ... for DOSING PIPE-NO 1


- (VP ) PRESSURE RAMP after DC

K 18. ... for DOSING PIPE-NO 2


- (VP ) PRESSURE RAMP after DC

03.03.00
= setup date
1
32.00 (Vp) = Pres. ramp after DC (mbar/s)

K18. P/t-MIN - 80/2 =DOSING PIPE NO 1:


03.03.00

= setup date

33.00 (Vp) = Pres. ramp after DC (mbar/s)

The setup data for kg-DIAGRAM is saved in a


permanent memory, which is protected against data
loss (e.g. at power failure) by a buffer battery. The
data can at any stage be modified.
ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
THE
INSTRUCTIONS IN THIS MANUAL.

SAFETY

SETUP MODE

WESTOMAT P ro Dos DPC


OPERATING MANUAL

kg-DIAGRAM
07.05

2-2

0705-B.doc

Version: 03.00 B

DOSING CONTROL

ATTENTION (continued)
The access to the setup mode can be locked by a
code. The code lock (freely selectable CODE
number) prevents unauthorised manipulations in
the BASIC SETTINGS of the Pro Dos DPC and is
entered and saved in the log (K 12).

SETUP MODE - STRUCTURE


The setup mode consists of menu-driven programmes:

REFERENCE VOLUMES - Setup programme for


dosing and measuring of actual values (volumes in
kg and respective ACTUAL counters) of the
individual REFERENCE DOSING VOLUMES
(RDV):

this setup mode is accessible from the selection


mode by pressing multi-function key F 5.

see chapter 07.05.1

OPERATING DATA - Setup mode for the


calculation of the actual dosing volume range (from
smallest to largest dosing volume) of the
WESTOMAT . This setup is accessible by
pressing the multi-function key F 4 in the selection
mode and requires the following entries and
selections:

see chapter 07.05.2


REFERENCE DATA - transfer of already saved
data as REFERENCE VOLUMES:

this setup mode is accessible from the


selection mode by pressing multi-function
key F 5.

MODIFY DATA - option to subsequently expand


the dosing volume range for dosing with the
WESTOMAT (without realizing the respective
RDV):

this setup mode is accessible from the


selection mode by pressing multi-function
key F 4 .

After the OPERATING DATA is setup and


saved, a new kg-dosing volume (by selection
kg-DOS: NEW) must be entered.

10.03.00
HEATING
SETUP MODE:
13:34:54
SCAN=CELL
DOSING-kg-DIAGRAM
F = MENU / ESC=back
F4 = OPERATIONAL DATA: data ENTRY
for OPERATIONS-kg-DIAGRAM
F5 = REFERENCE-VOLUMES: dosing and
data for REFERENCE- kg-DIAGRAM
INFO

F1

OPERAT. REFERENCE
DATA
VOLUMES

F2

F3

F4

F5

10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
kg-DIAGRAM-INPUT
F = MENU / ESC=back
K22. OPERATION-kg-DIAGR. 65/21 mm-NO 1:
F4 = MODIFY DATA
in present OPERATION-kg DIAGRAM
F5 = REFERENCE DATA:
take over data from REFERENC.VOLUME
to OPERATION-kg DIAGRAM
INFO

F1

MODIFY
DATA

F2

F3

F4

REFERENCE
DATA

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
kg-DIAGRAM
07051-B.doc

Version: 03.00 B

1-8

REFERENCE-(DOSING)-VOLUMES (RDV)

07.05.1

In the setup for option for REFERENCE VOLUMES,


the actual data for the kg-DIAGRAM of dosing volumes
of the Pro Dos DPC must be entered.
The following procedures are completed in this setup
programme:

Dosing (casting) of the programmed REFERENCEDOSING-VOLUMES (RDV), while the Pro Dos
DPC automatically calculates the specific ACTUAL
counter values

Weighing of casts with RDV

Entry and saving of calculated kg-value - assigned


to the individual RDVs

This procedure is carried out according to the following


DCM-DIE signals:

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


DIE CLOSED .................................. I-20 / I-21
DIE READY FOR INJECTION .......... I-22 / I-23
PLUNGER IN BACK POSITION ................ I-24

ATTENTION
Important instructions for RDV setup:

K21. REFERENCE-kg-DIAGR. 65/21-NO 1:


60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
01 =
124
20%
02 =
309
50%
03 =
464
75%
04 =
588
95%
05 =
619
M=MAX%
06 =
1856
M+0.75s
07 =
3094
M+1.25s
08 =
4331
M+1.75s
09 =
5569
M+2.25s
10 =
6806
M+2.75s

Prior to dosing the RDV, the die-specific dosing


volume range (smallest and largest dosing volume
in kg) must be defined together with the operator of
the WESTOMAT .

The programme settings are as follows:


01 to 04 - reduced feed pressure and shortest
dosing time (0.25 sec)
05 - M = MAX-feed pressure and shortest
dosing time (0.25 sec)
06 to 09 - M = MAX-feed pressure and dosing
time extended by 0.5 sec each
10 - M = MAX-feed pressure and shortest
dosing time of 2.75 sec - dosing time to be
prolonged, if required

The dosing for RDV 01, 02 and 03 must always be


carried out.

Depending on the operating parameters for:


- MAX-FEED PRESSURE
PRESSURE RAMP after DC
the actual dosing pipe size
The following values are to be expected at the
realization of RDV-05:
- for 40/12-mm dosing pipes ..up to ca. 0.7 kg
- for 40/16-mm dosing pipes ..up to ca. 1 kg
- for 50/18-mm dosing pipes ..up to ca. 1.5 kg
- for 65/21-mm dosing pipes ..up to ca. 2 kg
- for 80/28-mm dosing pipes ..up to ca. 3 kg
- for 80/28-mm dosing pipes ..up to ca. 3.5 kg
- for 100/35-mm dosing pipes ..up to ca. 5 kg

RDVs 06 and higher can only be realized if the


RDV-05 has been completed.

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REFERENCE-(DOSING)-VOLUMES (RDV)
07.05.1

2-8

07051-B.doc

Version: 03.00 B

DOSING CONTROL

ATTENTION (continued)

In order to prevent the overfilling of the DCM shot


sleeve, estimate the available capacity prior to
dosing the next RDV.

Larger dosing volumes that cannot be realized due


to insufficient capacity of the DCM shot sleeve,
must be carried out at a later stage. Alternatively,
enter in position 10 in OPERATING-kg-DIAGRAM see chapter 07.05.2

If the RDV procedure must be interrupted, save the


currently achieved status and continue procedure
by accessing setup option MODIFY.

The dosing of RDVs must be carried out at


FURNACE FULL with melt at operating temperature
and closed refill cover.

The WESTOMAT and associated assemblies


(pneumatic unit, dosing pipe, refill device, DC
scanning, supply channel) must be in perfect
working order.

Set connected DCM to position MANUAL

Prior to starting the RDV procedures, remove all


aluminium residue from dosing pipe, the DC
device, the outlet channel and the shot sleeve.

The metal feed during a RDV procedure must


be closely monitored and the EMERGENCY
OFF key must immediately be activated if there
are any disturbances.

After completed RDV cycle, wait until the cast


has solidified. Carefully remove the (hot) metal
from the open DCM die by means of the
plunger. Label cast according to RDV
procedure.

Measure the weight of the cooled metal blocks


with an accuracy of at least 0.1 and enter this
weight in the system.

The individual REFERENCE VOLUME data and the


setup date are automatically recorded in LOG K 21 for
dosing pipe no. 1 and in LOG K 23 for dosing pipe no.
2.
SETUP PROCEDURE
- see also chapter 07.00.
In BASIC STATUS of the Pro Dos DPC, press:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

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


P r o D o s

multi-function key

F 2 = SETUP

DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE:

SETUP MODE
Kg-DIAGRAM

REFERENCE-(DOSING)-VOLUMES (RDV)
07051-B.doc

Version: 03.00 B

10.03.00
13:34:57
F = MENU / ESC=back

F1

F3

F4

The display changes to the general SETUP MODE:

=
=
=
=
=

values of the individual setup options:


= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

07.05.1

The visualisation field shows the currently saved

SETUP of OPERATING DATA for:


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

3-8

Select - DATA ENTRY by pressing


multi-function key

F5

F4 .

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL

F4

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for REFERENCE DATA of
the kg-DIAGRAM is now accessible:
- For entry of OPERATING DATA - see chapter
07.05.2.

- REFER TO SAFETY INSTRUCTIONS OF


MANUAL
******

press multi-function key

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F4

The display form with instructions appears

10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

Press key
The SETUP MODE for REFERENCE DATA of
the kg-DIAGRAM is now accessible:
- For entry of OPERATING DATA - see chapter
07.05.2.

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REFERENCE-(DOSING)-VOLUMES (RDV)
4-8

07.05.1

07051-B.doc

The display changes to selection mode of


OPERATING DATA and REFERENCE VOLUMES:

Select - REFERENCE VOLUMES by pressing

Version: 03.00 B

DOSING CONTROL

10.03.00
HEATING
SETUP MODE:
13:34:54
SCAN=CELL
DOSING-kg-DIAGRAM
F = MENU / ESC=back
F4 = MODIFY DATA: in present
OPERATION kg-DIAGRAM
F5 = REFERENCE-VOLUMES: dosing and
data for REFERENCE- kg-DIAGRAM
INFO

multi-function key

OPERAT. REFERENCDATA
VOLUMES

F5 .

F1

F2

F3

F4

F5

The display changes to selection mode.

If two different dosing pipes have been entered


in the LOG, the respective dosing pipe must be
selected here

10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
= PIPE SELECTION, ENTER / ESC=back
SELECTION DOSING PIPE
65 /21 mm NO 1 = DOSING PIPE

80 /24 mm NO 2 = DOSING PIPE

by pressing
or

cursor in dosing pipe line

and press key


The display changes to selection mode for
DELETE or MODIFY:

10.03.00
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
REFERENCE-VOLUMES
= PIPE SELECTION, ENTER / ESC=back
SELECTION DOSING PIPE
65 /21 mm NO 1 = DOSING PIPE

80 /24 mm NO 2 = DOSING PIPE

If only one dosing pipe has been entered in the


LOG, continue with DELETE or MODIFY:

ATTENTION
Only use DELETE if none of the available data
is of any use.
- DELETE saved data or select
- MODIFY to modify, extend and add data or to
repeat procedure:

Press
or
MODIFY

to place cursor in line

and press key


The display changes to selection mode for
Reference-Dosing-Volumes (RDVs)

10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
= PIPE SELECTION, ENTER / ESC=back
SELECTION: DELETE or MODIFY
DELETE:
- delete existing data and
create NEW DATA
MODIFY:
- modifying, expanding or repetition
of existing data
INFO

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE
Kg-DIAGRAM

REFERENCE-(DOSING)-VOLUMES (RDV)
07051-B.doc

Version: 03.00 B

10.03.00
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
REFERENCE-VOLUMES
,EXT-KEY DOS-ON /instruction/ ESC=back
K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
01 =
124
20%
02 =
309
50%
03 =
464
75%
04 =
588
95%
05 =
619
M=MAX%
06 =
1856
M+0.75s
07 =
3094
M+1.25s
08 =
4331
M+1.75s
09 =
5569
M+2.25s
10 =
6806
M+2.75s
INFO
DOSING

5-8

07.05.1

In the RDV selection mode, the display shows the


following data:

diameter of selected dosing pipe


pre-set MAX-feed pressure (P -FD)
NOMINAL counter values
reduced feed pressure for RDV 01 to 04
dosing times with MAX-feed pressure - for RDV 06
to 10
not displayed is the dosing time for RDV 01 to
05 of 0.25 sec
the dosing time displayed for RDV 10 (2.75 sec)
can be extended, if necessary
If the previous RDV data has not been deleted, the
previous dosing volumes are displayed under kgDOS and their counter values are displayed under
NOMINAL counter.
Press
or

to place cursor in RDV line (01)

and press key


and continue as described for DOSING ON:

F1

F2

F3

F4

F5

10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
Position error: I-24 = 1 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM)

= 1

- PLUNGER was not moved:


- move PLUNGER compl. in FRONT- and
BACK into END POSITION!

Press key

F 5 = DOSING

The display changes to query status (F5STATUS),


establishing
whether
the
WESTOMAT and the DCM are ready for
injection:
- In the above example, no error occurred and
only the plunger, according to the operating
instructions, must be moved back and forth

DCM plunger is moved out

No position error occurred. Close DCM DIE


in switch position MANUAL according to
operating instruction.

the DCM die is closed in position MANUAL.

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


I-24 PLUNGER IN BACK POSITION (DCM)

= 0

- PLUNGER not in END POSITION:


- move PLUNGER compl. in FRONT- and
BACK POSITION !
EXT-KEY DOS-ON /instruction/ ESC=back
Instruction for MANUAL DOSING:
- CLOSE DCM-DIE in position MANUAL
completely !
EXT-KEY DOS-ON /instruction/ ESC=back
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
- DCM-DIE to be closed in
MANUAL POSITION!
INFO

DOSING

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REFERENCE-(DOSING)-VOLUMES (RDV)
6-8

07.05.1

07051-B.doc

The DCM die is further closed in position


MANUAL

Version: 03.00 B

DOSING CONTROL

10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
EXT-KEY DOS-ON /instruction/ ESC=back
To DOSING by HAND:
I-19 DIE CLOSES
(DCM) ........... = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
- DCM-DIE to be closed in
MANUAL POSITION!

The DCM die is fully closed in position


MANUAL = ready for injection.
- Press and hold the external key DOS-ON to
activate TOP-STOP.

EXT-KEY DOS-ON /instruction/ ESC=back


To DOSING by HAND:
DCM-DIE = READY FOR DOSING!

External key DOS-ON has been pressed and


TOP-STOP is activated.

TOP-STOP = activate
TOP-STOP = is being prepared
- this operational mode is selected
- hold external key DOS-ON
until TOP-STOP ready for operation!
INFO

The furnace chamber pressure for TOPSTOP-HOLD is reached (oval display dark),
the TOP-STOP is activated and the RDV
dosing process can be started.

MODIFY
DATA

DOSING

MANUAL
SETUP MODE:
DOSING
SCAN=CELL
REFERENCE-VOLUMES
... ON
DOS-by-HAND or F5/DOS-OFF=back
t6

t7

DCM-DIE
TS=

DC
t2

RDV-01: NC=
AC=
t3=
t4=
t3

t4

t5

WESTOMAT: AVAILABLE = 890 kg MELT


INFO

Press key

SETUP
START !

F 5 to start RDV cycle:

... Multi-function key F 5 pressed and

F1

F2

F3

F4

F5

RDV cycle STARTED:


MANUAL
SETUP MODE:
DOSING
SCAN=CELL
REFERENCE-VOLUMES
... RUN
Taster DOS von HAND oder F5 = DOSIEREN

PRESSURE-START to DC from TOPSTOP.

t6

RDV-01: NC=
AC=
t3=
DC
t4=

t7

DCM-DIE
TS=
t2

p = 31.74
INFO

t3

nc =

t4

t5

ac =
DOSING
by HAND

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

SETUP MODE:
REFERENCE-VOLUMES
t6

t7

DCM-DIE
TS=

DC
t2

p = 36.14

t6

REFERENCE-(DOSING)-VOLUMES (RDV)
07051-B.doc

RDV-01:NC=
AC=
t3=
t4=
t3

t4

ac =

DCM-DIE

RDV-01: NC=
AC=
t3=
t4=

t7

DC
t2

p = 41.54

t3

t4

nc =

ac =

DCM-DIE

RDV-01: NC=
AC=
t3=
t4=

t7

TS=

DC
t2

p = 39.96
INFO

Version: 03.00 B

7-8

07.05.1

MANUAL
DOSING
SCAN=CELL
... RUN

nc =

TS=

t6

SETUP MODE
Kg-DIAGRAM

t3

nc =

t4

DC is reached. Feed pressure rise and metal


feed are initiated.

Feed pressure is reached. Dosing time is


initiated and metal feed continues.

Dosing time is reached, the furnace chamber


is deaerated, the t5-LAG TIME is started and
the metal feed END is reached.

t5-LAG TIME is completed, the RDV cycle is


COMPLETED and the instruction to activate
the external key DOS-OFF appears. The
process data (e.g. for RDM-01) are
displayed:
- NC = NOMINAL counter value
- A C = ACTUAL counter value
- t 3 = pressure rise time from DC to feed
pressure REACHED
- t 4 = dosing time from feed pressure
REACHED to RDV-01 dosing volume
reached (if ACTUAL counter =
NOMINAL counter)

t5

t5

t5

ac =
DOSING
by HAND

MANUAL
SETUP MODE:
DOSING
SCAN=CELL
REFERENCE-VOLUMES
... END
USE = KEY DOS-OFF
t6

t7

DCM-DIE
TS=

DC
t2

p = 1.37
INFO

RDV-01: NC=124
AC= 187
t3=0.432
t4=0.260
t3

nc =

t4

t5

ac =
DOSING
by HAND

SETUP MODE:
REFERENCE-VOLUMES

10.03.00
13:34:35

HEATING
SCAN=CELL

ENTER = continue
K21. OPERATION-kg-DIAGR.65/21mm = NO

1:
OPERATING INSTRUCTION:
after DOSING and SOLIDIFICATION:
- OPEN DIE and
- ADVANCE PLUNGER !
INFO
DOSING

After pressing of external key DOS-OFF, the


operating instruction is displayed.

The display changes to instruction mode.

After the RDV cast has solidified in the DCM


shot sleeve, open DCM die and:
remove hot cast and label (RDV-01)
weigh cooled cast
(in kg with an
accuracy of at least 0.1)

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

REFERENCE-(DOSING)-VOLUMES (RDV)

07051-B.doc

8-8

07.05.1

Press key
Display returns to RDV selection form:

The line of the realized RDV show the


ACTUAL counter value
The calculated RDV kg-value can be entered
now or at a later stage
Save values (even if no kg-values have been
entered) and continue at a later stage

For additional RDV-processes, follow above


instructions for RDV-01.

NOTE for RDM-10:

The displayed dosing time of 2.75 sec can


be extended, if necessary:
Press key

to place cursor

on the displayed time for RDV-10 and enter


previously calculated time
Press key

SAVING REFERENCE-VOLUMES

Version: 03.00 B

DOSING CONTROL

10.03.00
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
REFERENCE-VOLUMES
, INPUT, ENTER and MEMO / ESC=back
_K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
01 = #,00
124
187
20%
02 =
309
50%
03 =
464
75%
04 =
588
95%
05 =
619
M=MAX%
INFO
DOSING

10.03.00
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
REFERENCE-VOLUMES
,
INPUT,
ENTER
and
MEMO
/
ESC=back

_K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
06 =
1856
M+0.75s
07 =
3094
M+1.25s
08 =
4331
M+1.75s
09 =
5569
M+2.25s
10 =
6806
M+2.75s
INFO

- the LED of the MEMO key is blinking (ready to


save):

To save data - press key

F1

MEMO and:

MEMORY = YES:

The new values are saved

F3

DOSING

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

10.03.00
SETUP MODE:
13:34:54
REFERENCE-VOLUMES
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY

F5

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup procedure for the REFERENCE-VOLUMES


is now completed.

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

SETUP MODE
kg-DIAGRAM
07052-B.doc

DOSING CONTROL

Version: 03.00 B

1-6

OPERATING DATA

07.05.2
In the setup option for OPERATING DATA, the data
for the OPERATING-kg-DIAGRAM for dosing volumes
must be entered and saved in the Pro Dos DPC
programme. The smallest and largest dosing volume
define the dosing volume range of the WESTOMAT .
For the completion of this setup procedure, the values
established in the setup process for REFERENCE
VOLUMES must be transferred and saved. The dosing
range can be extended at a later stage to suit different
dies. Proceed as follows:

Save next higher dosing volume (up to volume for


RDV 10), or

increase and save dosing time (e.g. for the already


saved RDV 10).

The setup date for OPERATING DATA is automatically


recorded in LOG K 22 for dosing pipe no. 1 (LOG K 24
for dosing pipe no. 2).

SETUP PROCEDURE
- see also chapter 07.00.
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
EXT-KEY DOS-ON or F5 = DOSING
!

In BASIC STATUS of the Pro Dos DPC, press:

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
03.03.00
= DATE OF SETUP DATA

INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING

F2

SETUP MODE:

F3

F4

F1

multi-function key

The display changes to the general SETUP MODE:

F 2 = SETUP

The visualisation field shows the currently saved


values of the individual setup options:
= 1 - if data is complete
= 0 - if data is incomplete
or if there is no data

F5

10.03.00
13:34:57
F = MENU / ESC=back

SETUP of OPERATING DATA for:


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

=
=
=
=
=

1
1
1
1
1

AVAILABLE = 1040 kg MELT


FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING

F2

F3

F4

F5

Select - DATA ENTRY by pressing


multi-function key

F4 .

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING DATA
07.05.2

07052-B.doc

2-6

Version: 03.00 B

DOSING CONTROL

ATTENTION

THESE SETTINGS MAY ONLY BE MADE BY


QUALIFIED AND SPECIFICALLY TRAINED STAFF

ALWAYS
COMPLY
WITH
SAFETY
INSTRUCTIONS IN THE OPERATING MANUAL
Access to this SETUP OPTION can be locked by
code lock. The code lock prevents unauthorised
manipulation at the Pro Dos DPC and is recorded
in the log (K 12).
If the SETUP MODE is code-locked,

press multi-function key

F4

The display form with instructions for entry of


the code number appears

Enter code number and press


The SETUP MODE for REFERENCE and
OPERATING DATA of the kg-DIAGRAM is now
accessible:
- For entry of REFERENCE-VOLUMES - see
chapter 07.05.1.

10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
******

= ENTRY CODE-N and ENTER

If the SETUP MODE is not code-locked,

press multi-function key

F4

The display form with instructions appears

Press key
The SETUP MODE for REFERENCE and
OPERATING DATA of the kg-DIAGRAM is now
accessible:
- For entry of REFERENCE-VOLUMES - see
chapter 07.05.1.

10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
ATTENTION: OPER. INSTRUC. / ESC = back
- THIS SETUP PROCEDURE MAY ONLY BE
PERFORMED BY AUTHORISED PERSONNEL
- REFER TO SAFETY INSTRUCTIONS OF
MANUAL
CONTINUE PROCEDURE WITH ENTER

The display changes to selection mode for


OPERATING DATA and REFERENCE VOLUMES:

Select - OPERATING DATA by pressing


12.10.99
HEATING
SETUP MODE:
13:34:54
SCAN=CELL
DOSING-kg-DIAGRAM
F = MENU / ESC=back
F4 = MODIFY DATA: in present OPERATION kgDIAGRAM
OPERATION kg-DIAGRAM
multi-function key

F4 .

F5 = REFERENCE-VOLUMES: dosing and


data for REFERENCE- kg-DIAGRAM
INFO

F1

OPERAT. REFERENCDATA
VOLUMES

F2

F3

F4

F5

WESTOMAT ProDos DPC


OPERATING MANUAL

SETUP MODE
Kg-DIAGRAM

OPERATING DATA
07052-B.doc

DOSING CONTROL

Version: 03.00 B

12.10.99
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
kg-DIAGRAM-INPUT
= PIPE SELECTION, ENTER / ESC=back

3-6

07.05.2

The display changes to selection mode.

SELECTION DOSING PIPE

If two different dosing pipes have been entered


in the LOG, the respective dosing pipe must be
selected here.

65 /21 mm NO 1 = DOSING PIPE


80 /24 mm NO 2 = DOSING PIPE

by pressing

12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
= PIPE SELECTION, ENTER / ESC=back

or
line

SELECTION DOSING PIPE

place cursor in dosing pipe

and press key

65 /21 mm NO 1 = DOSING PIPE

The display changes to selection mode.

- Select MODIFY to extend the dosing


volume range, or

12.10.99
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
kg-DIAGRAM-INPUT
F = MENU / ESC=back

INFO

F1

MODIFY
DATA

F2

F3

F4

REFERENC
DATA

F5

12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
=
DATA
LOG
/
ESC=back

K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
01 = 0.30
124
196
20%
02 =
309
50%
03 = 1.75
464
871
75%
04 =
588
95%
05 = 2.70
619
1073
M=MAX%

transfer

the

If only one dosing pipe has been entered in the


LOG, continue with:
- MODIFY to extend the dosing volume
range, or
-

K22. OPERATION-kg-DIAGR. 65/21 mm-NO 1:


F4 = MODIFY DATA
in present OPERATION-kg DIAGRAM
F5 = REFERENCE DATA:
take over data from REFERENC.VOLUME
to OPERATION-kg DIAGRAM

REFERENCE DATA to
REFERENCE VOLUMES

REFERENCE DATA to
REFERENCE VOLUMES

transfer

the

SETUP EXAMPLE of REFERENCE DATA:

Select - REFERENCE DATA by pressing


multi-function key

F5 .

The display changes to the table with


REFERENCE VOLUMES. To save (transfer
of values),

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING DATA
07052-B.doc

4-6

07.05.2

- press

to place cursor

in required line. The data values of the


realized RDV are displayed.
- Press

and SAVE OPERATING DATA


- the LED of the MEMO key is blinking (ready to
save):

To save data - press key

F1

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

DOSING CONTROL

12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
=
DATA
LOG
/
ESC=back

K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
06 =
1856
M+0.75s
07 = 3.85
3094
3687
M+1.25s
08 =
4331
M+1.75s
09 = 5.20
5569
6183
M+2.25s
10 =
6806
M+2.75s
INFO

MEMORY = YES:

The new values are saved

F3

MEMO and:

Version: 03.00 B

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

The setup procedure for OPERATING DATA (transfer


of REFERENCE DATA) is now completed.

Press key
status

ESC - display returns to initial

press key
STATUS

ESC - display returns to BASIC

21.03.99
SETUP MODE:
13:34:54
kg-DIAGRAM-INPUT
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED
F5 - BACK TO ENTRY
MEMORY
= YES

F1

MEMORY
= NO

F2

F3

BACK TO
ENTRY

F4

F5

SETUP EXAMPLE of MODIFY DATA:


If data must be modified at a later stage, e.g.
expansion of saved dosing volume range, proceed
as follows:

Access kg-DIAGRAM selection mode:

select

K22. OPERATION-kg-DIAGR. 65 /21 mm-NO 1:


F4 = MODIFY DATA
in present OPERATION-kg DIAGRAM
F5 = REFERENCE DATA:
take over data from REFERENC.VOLUME
to OPERATION-kg DIAGRAM

MODIFY DATA

Select - MODIFY DATA by pressing

multi-function key

12.10.99
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
kg-DIAGRAM-INPUT
F = MENU / ESC=back

F4 .

INFO

F1

MODIFY
DATA

F2

F3

F4

REFERENC
DATA

F5

SETUP MODE
Kg-DIAGRAM

WESTOMAT ProDos DPC


OPERATING MANUAL

DOSING CONTROL

OPERATING DATA
07052-B.doc

Version: 03.00 B

5-6

07.05.2

- Press

12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
= DATA LOG / ESC=back

to place cursor

in line of RDV-10
ATTENTION

K21. REFERENCE-kg-DIAGR. 65/21-NO 1:


60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
01 = 0.30
124
196
20%
02 =
309
50%
03 = 1.75
464
871
75%
04 =
588
95%
05 = 2.70
619
1073
M=MAX%

For not realized RDVs, only the precalculated dosing volume (kg-DOS) without
ACTUAL counter value is displayed.

INFO

NOTE for RDM-10:

12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
, ENTER = take over reference

The displayed dosing time of 2.75 sec


can be extended, if necessary:
Press key

K21. REFERENCE-kg-DIAGR. 65/21-NO 1:


60 mbar = P-fd / MAX-feed pressure
No. kg-DOS. SET-count. ACT-count. P-FD
06 = 3.30
1856
M+0.75s
07 = 3.85
3094
3687
M+1.25s
08 = 4.55
4331
M+1.75s
09 = 5.20
5569
6183
M+2.25s
10 = 5.82
6806
M+2.75s

to place cursor

in the line of the dosing time for RDV-10


and enter new time (greater than 2.75
sec).
- Press key
The new dosing volume is displayed as
kg-DOS.

INFO

SAVING OPERATING DATA


- the LED of the MEMO key is blinking (ready to save):

To save data - press key


21.03.99
SETUP MODE:
13:34:54
kg-DIAGRAM-INPUT
ATTENTION: DATA HAVE BEEN MODIFIED!
F1 - SAVE DATA MODIFICATION
F3 - DO NOT SAVE DATA MODIFICATION
KEEP DATA UNMODIFIED

F1

F5 - BACK TO ENTRY
MEMORY
= YES

MEMORY
= NO

BACK TO
ENTRY

F1

F2

F3

F4

F5

MEMORY = NO:

The new values are deleted and the


previous values remain saved; the
display returns to initial status

F5

MEMORY = YES:

The new values are saved

F3

MEMO and:

BACK TO ENTRY:

The previous values are not overwritten;


the display returns to the entry form,
where the newly entered values are
displayed;
additional
entries
and
modifications can be made.

SETUP MODE
Kg-DIAGRAM

WESTOMAT P ro Dos DPC


OPERATING MANUAL

OPERATING DATA
07.05.2

6-6

07052-B.doc

Version: 03.00 B

DOSING CONTROL

The setup procedure for OPERATING DATA of the kgDIAGRAM (subsequent expansion of dosing volume
range) is now completed:

Press key

ESC - display returns to initial status

press key
STATUS

ESC - display returns to BASIC

The dosing volume (F4 = kg-DOS: NEW) must now


be setup again - see chapter 02.01.2.

***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 65/21mm 13:34:57
F4 = kg-DOS: NEW
!

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


P r o D o s
DPC-V1.01-05 = DIE-CASTING-VERSION
10.03.00
= DATE OF SETUP DATA
INFO

F1

AVAILABLE = 1040 kg MELT


SETUP
OPERAT. kg-DOS:
MODES
NEW

F2

F3

F4

F5