DAP

Powder Auxiliaries Dissolving Unit

DAP Software Manual

ADDRESS: Via Divisione Julia N. 15 - 36031 Dueville (VI) - ITALIA

TECNICAL ASSISTANCE: Tel. +39-0444-366000 Fax. +39-0444-592469
e-mail: help@colorservice.net
INDEX

Index............................................................................................................... 2
Introduction.................................................................................................... 3
Start Up............................................................................................................ 3
Archives Management.................................................................................. 5
Product.................................................................................................. 5
Machine................................................................................................ 11
Exit Thresholds...................................................................................... 16
Stock Management........................................................................................ 17
Read Configuration File.................................................................................. 18
Reset Cycles.................................................................................................... 18
Dosing Management.......................................................................................... 19

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INTRODUCTION
DAP is an automated system for weighing and dissolving powder chemicals,
controlled by a software that allows complete control of all operations that the
machine can perform.
This handbook aims to guide the user to a proper and effective use of software.

START UP
At the start appears the screen shown below.

The screen represented is the main menu.

Clicking on an item of the menu bar access to an appearance on the menu or
you run directly a function.
In the first case appears a list of functions. When the mouse flows the drop shows
the selected item; to choose an item you must click on it.

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In the bottom right you can read the current date and time.
In the bottom left you can control the setting active or not of the
communication between the DAP and the PLC (logical processor machine
Color Service in the electrical panel) and between the DAP and the Supervisor
Color Service.
To exit the screen, you must select the menu bar the click EXIT.

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ARCHIVES MANAGEMENT
PRODUCTS MANAGEMENT

This is a screen that allows you to view and modify the technical characteristics
of each powder chemical inserted.
Declaring the number of the product of special interest in the cell and then
pressing the ENTER key, or selecting the product from the list, than appears the
characteristics of the product:

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• code which the product is stored in Corporate Information System, full
description;
• Concentration: if a product has a yield of 50% means that if the request is a
treasure 100 g Color Service system should weigh 200 grams so 'he product is
really effective; at 100% the amount request is the same of the really
effective;
• Specific Weight: ratio weight/volume of the product;
• Price: is the price of the product per kilogram;
• Screen Color: is the color that distinguishes the product graphically in the
stock representations;
• Product type: Powder chemical for DAP.

Others [principal] data are grouped into four main categories:

PRODUCT TYPE

• Silo number: it is the identification silo number where stored this product;
• Loading measure unit: chose the unit (grams, cc, kg, liters);
• Maximum capacity: is the silo’s capacity (in grams) when the product is
stored;
• Minimum Stock: is the threshold corresponding to the minimum level of
stocks;
• Stock: current silo’s quantity (in grams);

DOSING MANAGEMENT DAP

• Enabled line # 1 / 2: the DAP can present two independent tanks of levy and
sending product (including pump line, flow-meter, water valve for washing
line, blowing valve, withdrawal group valves); will need to enable for each
product if physically can be sent to the line 1, line 2 or both;
• Unit dose: chose the unit (grams, cc, kg, liters, Lb);
• Minimum weighing, maximum weighing: are the values of minimum and

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 maximum possible dose for a selected product;
• Percentage error for: If during the dosage operation exceeded the quantity
desired, a software performs a calculation to determine the percentage of
error in dosage.
If is only exceeded the alarm percentage is only sent a signal to the
supervisor.
If is exceeded the stop percentage the dosing cycle is interrupted with a
message on the screen for the operator, that must choose if accepted the
dosage or abort the recipe;
• Type of restore: If the DAP is in dosing but the product don’t exit it tries to
make a restore in the silo (with a pump, with vibration, or not);
• Restore number: number of repetitions allowed for the restore operations.

DISSOLVING UNIT MANAGEMENT

• Solubility: it is the solubility ratio in gr/lt needed for the dissolution of the
product; if a product has a solubility of 1000 means the machine use 1 liter of
water to dissolve 1 Kg of product; if the parameter is 700 means the machine
use 1 liter of water to dissolve 700 gr of product;
• Dissolving cycle [sec.][°C ]: The first parameter is the dissolving time in
second, the second parameter is dissolving temperature in °C;
• Antifoam input: If a DAP system use also a antifoam agent with this
parameter you can set a time of antifoam input for each product dose;
• Additional agent: If a DAP system use also a parameter agent with this
parameter you can set a percentage of agent for each product dose;
• Drain rinses: It is the number of washing in drain after product dissolving and
sending;
• Force hot water: Set this box if for this product you want to use only the hot
water to dissolve.

MANAGEMENT THRESHOLDS

Click the button MANAGEMENT THRESHOLDS and appear other important

parameters:

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• Auto thresholds: It is the automatic set thresholds;
• Nr screws installed: It is a number of screw for the selected silo (generally 1);
• Thresholds for pulse min s.: under this weigh parameter (grams) the screw start
to pulse for dose a little quantity of product to make precise a weighing;
• Threshold for speed 1…6: This is a weigh parameter (grams); means the screw
work at speed 1…6 upper this parameter (1…6); change these parameters if
the dosing is slowly or incorrect;
• Max speed, Min speed: These two parameter are between 1 and 7
(generally min=1, max=7);
Click CLOSE MANAGEMENT THRESHOLDS to return to Dosing Management DAP.

Delete
Clicking on the button DELETE obtained the current product cancellation from
the database.

To delete a product:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item PRODUCTS MANAGEMENT;

In the screen that appears positioned in the first box and enter the product
number to be erased, then press ENTER;

As an alternative to the previous point, click LIST, when the products list
appears, click on the product which you want delete;

Click Delete: you're asked for confirmation to proceed in the cancellation; if
you aren’t sure to delete the product click NO and the delete operation will
be cancelled;

If you are sure to proceed with the product cancellation click on YES;
appear the request of Password: if you press CANCEL the erase operation is
canceled; to proceed, you have to type the password and press ENTER.

Save
Clicking on the SAVE button you get the product saving in the database taking
into reference data displayed on the screen; the saving overwrites the
characteristics of an existing product or add a new product in the database.

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To modify a product data:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item PRODUCTS MANAGEMENT;

In the screen that appears positioned in the first box and enter the product
number to be erased, then press ENTER;

As an alternative to the previous point, click LIST, when the products list
appears, click on the product which you want modify;

With the mouse positioning the cursor in the box containing the data to be
modify; erase the old data and type the new;

Click Save: first appear a message that requires confirmation for product
registration; click NO if you don’t want to register the product, click YES to
proceed in the recording;

By proceeding in the recording appears the second message that asks if you
are sure to overwrite the data of the product; click NO if you don’t want to
override the product, click YES to proceed in the recording;

By proceeding appear the password request; if you press CANCEL the
modify operation will be annulled; to proceed, type the password and press
ENTER.

To add a product in the product management:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item PRODUCTS MANAGEMENT;

In the screen that appears positioned in the first box and enter the product
number to be erased, then press ENTER;

If the product already exists all boxes of the screen will be built with all its
features, this is the previous case of changing product; if you want to add a
product return above (positioned in the first box…);

Compiling data to be stored;

Click SAVE: first appear a message that requires confirmation for product
registration; click NO if you don’t want to register the product, click YES to
proceed in the recording;

By proceeding appear the password request; if you press CANCEL the

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 modify operation will be annulled; to proceed, type the password and press
ENTER.

Send Product List

To send to Color Service Supervisor data of all stored products click SEND
PRODUCTS LIST button.

Back Up
To do a database products Back Up (the path to the file copy shall be set by the
technicians Color Service in the configuration file of the program) click BACK UP
button.

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MACHINES MANAGEMENT

This is a screen that allows you to view and modify the technical characteristics
of each dosing destination tanks.
Declaring the alphanumeric code of the tank reference, the code which the
machine is registered in the Information System Company, the tank
alphanumeric code and then pressing the Enter key, or selecting the tank from
the list, displays the characteristics of the chosen tank:

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 • Machine code and tank code: the machine code and the tank code
uniquely identify the machine;
• Machine description: full tank name;
• Machine liters: total capacity of the machine in liters;
• Enabled line # 1 / 2: see management weighed in product management
(p. 5);
• Tank liters: capacity of the tank in liters;
• Dissolving unit type: select it from the menu’ (all dissolving unit);
• x e y coordinates of reference position in the distributor, unity that takes
the dosage of products and send it to the machine, in the case of
sending with monoline (single sending pipe with 3 way valves for each
destination) these parameters are not active;
• presence and possible value for end of line valves and drain valve (tank
sending and drain sending), for various needs (as tank capacity or need
for pie more) can be necessary to place a 3 way valve at the end
sending pipe so that the Color Service system can send the product in the
tank and washing in the drain destination.

The screen also allows access to certain functions:

Delete
Clicking on the button DELETE obtained the current tank cancellation from the
database.

To delete a tank:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item MACHINE MANAGEMENT;

In the screen that appears positioned in the first box and enter the machine
number to be erased, in the second box insert a tank number, then press
ENTER;

As an alternative to the previous point, click LIST, when the tanks list appears,
click on the tank which you want delete;

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Click Delete: you're asked for confirmation to proceed in the cancellation; if
you aren’t sure to delete the tank click NO and the delete operation will be
cancelled;

If you are sure to proceed with the tank cancellation click on YES; appear
the request of Password: if you press CANCEL the erase operation is
canceled; to proceed you have to type the password and press ENTER.

Save

Clicking on the SAVE button you get the tank saving in the database taking into
reference data displayed on the screen; the saving overwrites the
characteristics of an existing product or add a new product in the database.

To modify a tank data:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item MACHINE MANAGEMENT;

In the screen that appears positioned in the first box and enter the machine
number and in the second box the tank number to be erased, then press
ENTER;

As an alternative to the previous point, click LIST, when the machines list
appears, click on the tank which you want modify;

With the mouse positioning the cursor in the box containing the data to be
modify; erase the old data and type the new;

Click Save: first appear a message that requires confirmation for machine
registration; click NO if you don’t want to register the machine, click YES to
proceed in the recording;

By proceeding in the recording appears the second message that asks if you
are sure to overwrite the data of the tank; click NO if you don’t want to
override the tank, click YES to proceed in the recording;

By proceeding appear the password request; if you press CANCEL the
modify operation will be annulled; to proceed, type the password and press
ENTER.

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To add a tank in the machine management:

Select from the main menu the item ARCHIVES MANAGEMENT and sliding on
the dropdown click on the item MACHINE MANAGEMENT;

In the screen that appears positioned in the first box and enter the machine
number and in the second box the tank number to be erased, then press
ENTER;

If the tank already exists all boxes of the screen will be built with all its
features, this is the previous case of changing product; if you want to add a
product return above (positioned in the first box…);

Compiling data to be stored;

Click SAVE: first appear a message that requires confirmation for tank
registration; click NO if you don’t want to register the tank, click YES to
proceed in the recording;

By proceeding appear the password request; if you press CANCEL the
modify operation will be annulled; to proceed, type the password and press
ENTER.

Send Machine List

To send to Color Service Supervisor data of all inserted tank click SEND
MACHINES LIST button.

Back Up
To do a database machines Back Up (the path to the file copy shall be set by
the technicians Color Service in the configuration file of the program) click BACK
UP button.

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Units and Rinses

By pressing the button UNITS AND RINSES displays the tank and the line washing
of the selected machine:
• Tank washes table: washing serial number; washing liters; type of water (hot
or cold); destination (machine tank, end of line drain [3 way valve]); sent
(constant like flow-meters); blowing (sec .); free line (with return distributor in
the zero position).

Copy and Paste

By clicking COPY button you can copy the washing parameters for the
specific machine; by PASTE button you can paste the copied parameters
from a machine to an other machine.

Save
By clicking on the SAVE button you have the washing tank saving with new
features, this command works to overwrite washing data in a existing tank
and also in the saving of a new one.

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EXIT THRESHOLD MANAGEMENT

In the grid you can see the exit thresholds from one quantity to an other
quantity.
For example, now, if you dose 15000 grams of salt (or other DAP product) the exit
thresholds is 500 grams.
If the machine dosed up of 500 grams the software give you an alarm and you
can accept the error or discharge a recipe.

Save
By clicking on the SAVE button you have the settings saving.

Back Up
To do a database machines Back Up (the path to the file copy shall be set by
the technicians Color Service in the configuration file of the program) click BACK
UP button.

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STOCK MANAGEMENT

This is a screen that allows you to access in the program stock management
screen.
The boxes products with the quantity 'existing below the minimum level (see
product management) will flash with dark gray background.
By clicking on a box appear the product related data, including the current
quantity in the silos.

Product Load

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By clicking on the button PRODUCT LOADING, select one product, you can
change the present stock value, both positive and negative (loading and
unloading). Select also a right measuring unit.

READ CONFIGURATION FILE

Performs the INI configuration file reading.

RESET CYCLES
Make the cancellation (operator confirmation) of all cycles (DAP line # 1, etc.)
currently in working.
N.B.: make this operation only after you've COMPLETE the reset of electrical
panel of this Color Service machine and the first to put the switch from manual to
automatic. No cycle can resume from the point where it was previously
stopped.

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DOSING MANAGEMENT

The selection Dosage provides access to the represented screen, where you
can create manual recipes and the launch them or other recipes sent by the
supervisor (the concentrator system which all PCs dosing are connected).
The screen is divided mainly into four sections.

DOSING INSERT

The upper left section is the interface for the settlement of recipes; the data to
be included in the boxes are the head of the recipe and precisely:
• machine: the machine code of destination, as selected by the list (see
Machine management);
• tank: it is the machine tank destination that was addressed the recipe;
• batch or dyelot: identify code of the recipe working
• introduction: to identify the call of the dyeing recipe which a product is
dosing;
• redye is the value of a possible re-call (addition) for a same batch and

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introduction;
To compose a recipe, after completing the head data, you have to listing the
products in succession to be dose in the table below.
Each row of the table contains a product information related a to dose product,
subdivided as follows:
• N°: is the storage tank number where the product is stored, as selected by the
list (see Products);
• description: the description is associated with the product chosen, updated
automatically after you choose the product number;
• Measurement unit dosage for the product;
• Expected: it is the product required total amount;
• To dose: it is the amount calculated from the PC based on the product yield
set;
• Dosed: it is the amount real dosed (it is used only in reading when selecting a
recipe from the dosed historic);

For the chosen product you can see the amount available of the recipe
composition.

Products
The complete products list can be displayed by clicking on the button
PRODUCTS. To select a product from the list click on the line. The selected
product is inserted into the first empty row in the dosage composition table.

Machine Tanks
The complete machine list can be displayed by clicking on the button
MACHINES. To select a tank from the list click on the line: the selected tank will
go to complete the box below the words "Machine" ..

Save
After inserted the recipe you store and pass it on the waiting list by clicking the
button SAVE.

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To make a new recipe:

Position on the first box in the upper left ( "Machine");

Compiling the data of the destination machine and press ENTER (see
Machines management);

Type the tank code and press ENTER;

Type the batch code and press ENTER;

Type the call number and press ENTER;

Position the cursor on the first box in the upper left corner of the grid; enter
the product number to be weighed or select a product from this list (see
Products);

The description of the product is already filled; verify that the cursor is
positioned at the fourth column for the same line and insert the program
dosing quantity expressed in grams;

The quantity "to dose" is calculated automatically;

If you have any other products add to the list with the same procedure,
moving on the line below in the grid;

When there aren’t other products to add click on SAVE, the recipe will send
in the waiting list;

If there are some errors you will see the message on the screen.

DOSING LIST
The upper right section in the corner of the screen contains a table that you can
see a waiting dosing list or a dosed list. To switch from one list to another simply
click on the option.
Each row of the table contains information relating to a dosage, identified by:

• machine code: the dosage destination machine;

• tank;
• batch code;
• introduction;
• redye;
• date and time which the dosage was composed;

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• date and time which the dosage started on dose;
• date and time which the dosage ended on dose;
To watch all recipe information simply click on the line interest of the table: in
the top left appear the recipe selected information.

Clean
The CLEAN button allows you to clean up the table that you use to compose the
recipes; products are removed from the display but this command doesn’t
delete the saved recipes, which remain stored.

Delete
The DELETE button allows you to delete the selected recipe from the waiting
dosing list or from the dosed list.

Priority
By clicking on the square box placed alongside the words "priority" gives the
priority to a recipe, appears in the recipe section recipes, over all others on the
waiting list: the priority recipe go in top of the list and therefore will be the first
recipe to be performed. To be active a priority for the recipe need resave this
recipe.

Suspended
By clicking on the square box placed alongside the words "suspended" shall
suspend the recipe appears in the section recipes: when the recipe arrives in
top of the list don’t start if the suspension is active; the recipe don’t lost,
however, the position in the list. To be active a suspension for the recipe need
resave this recipe.

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Semaphore "Supervis" F7
By clicking on the semaphore you enable / disable the automatically receipt of
recipes from the Supervisor PC.
With the traffic light in "green" communication is enabled.

Semaphore "DAP 1 - 2" F5

A click on "red" Semaphore or press F5 activates the recipes loading process on
the waiting list, a click on the semaphore "green" or press F5 stop this process
(the dosing cycle, however, continues until all recipes loaded in this part finish).

DAP LINE #1
In the central section viewing the working dosage in line #1 of the levy and
sending products.
During a dosage you can see the information of the recipe in progress; in the
table you can read the products and washes that make up the recipe; the
amount actually dispensed it updates as the dosage proceeds.
When the cycle will complete you can see the end cycle message; then it will
display next recipe to be dose, the top recipe in the list.

Start Semaphore – Stop F11

A click on Semaphore - Start or press F11 active the cycle execution (reading
manual and automatic recipe; dosing; washes; ticket printing, etc.) of the
recipe currently loaded; click on Semaphore - Stop or press F11 key doesn’t
interrupt this cycle (it will finish) but simply prevents the execution of an other
recipe later (both manual and automatic).

“RESET” Label
By clicking on the RESET label of each cycle (after consent by the operator) is
erased the database containing the data of the cycle in progress.
The cycle will resume as if it was a new recipe.

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N.B.: make this operation only after you've COMPLETE the reset of electrical
panel of this Color Service machine and first to put the switch from manual to
automatic. The cycle cannot resume from the point where it was previously
stopped.

“STOP” Icon
The product dosing phase may have a manual interruption by the operator,
when need its; interruption is activated by clicking on the STOP.
Enabled interruption a window will appear with writing "manually weighing
stopped"; there are three possible options to interrupt a cycle, which are
activated by clicking on the button corresponding to:
-> Continue: resumed the dosage from the product which was in progress at the
time of the stop;
-> Skip to the next product: resumed the dosage from the next product in list;
-> Abort recipe: ending the dosage of the products, sending a dosed quantity
to the destination machine, and start the washing;

MESSAGE WINDOWS
In the green windows below each cycle are displayed messages: these inform
the dosing process [with hours of writing and value of Data Memories writing-
reading phase (to PLC) in progress].
In the small window beside you can see the number of step cycle currently in
progress.
There are also 2 white box where you can watch a Hot water temperature and
a Cold water temperature in the entry line.

ALARM RESET
Press this button to stopped the alarm.

EXIT
To exit from the dosage screen you must click on Exit.
It is possible exit from the screen only when it isn’t any recipes in dosing.

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 For information:

 +39-0444-366000  +39-0444-592469

 help@colorservice.net

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