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ll HMT® Pro-Fill System Manual

Pro-Fill, Automatic Fill System®Pricing Inform

ation

Pro-Fill System Assembly (Factory Installed)

Benchmark or ProFlex Tank Size (lb)

ProFill Assembly Part Number List Price US$

12-20 lb25-85 lb

135-200 lb

910-073910-074910-075

2,995.002,995.00 3,295.00

OFF

ON

DAC LOADER

Vacuum Control Module with misc. airline and power cord

Dri-Air Vacuum/Lid Assembly w/ Level Sensor

Vacuum Tube Assembly w/ Vibrator

Adhesive Drum # 910-079(Optional)

Tank Lid Clamp (2) Mounting Kit

Cart Assembly with Casters # 100-211 (Optional)

In-Field Retro-Fit Kits are available. Add $200. Contact HMT’s Tech Support Group for details.

Effective Date: 2/1/2017All prices are subject to change without notice

5/5/15 Ravi

2 Secure the lid by closing both clamps down on the lid assembly.

6

7

Slide the feeding tube over the exit portof the Vacuum feeder. Using the ring clamp and a flat head screw driver; tighten the clamp to secure the feeding tube to the exit port of the Vacuum.

43 Slide the feeding tube over the entranceport of the Dri-Air loader. Using the ring clamp and a flat head screw driver; tighten the clamp to secure the feeding tube to the entrance port.

Mount the air control kit to the desired location.Please note that the bracket provided is designed mount to the side of any Hot Melt Technologies melt unit. Yet capable of being mounted to any location that fits your needs.

5

1

Place the Dri-Air Loader and Lid assembly on to the tank assembly.

Pro-Fill Installation Instructions

8

Install airlines from the air control kit to the vacuum and agitator located on the wand.

Connect sensor cable to the sensor located on the lid. Connect sensor cable to the sensor located on the lid.

Plug the sensor cable into the front of the aircontrol kit.

DRI-AIR INDUSTRIES, INC.

Page 1 OPERATING MANUAL - DAC LOADERRevision 9/14/01

DAC COMPRESSED AIRLOADER

OPERATING MANUAL


Page 2OPERATING MANUAL - DAC LOADERRevision 9/14/01

DRI-AIR INDUSTRIES,

INC.16 THOMPSON ROADP.O. BOX 1020EAST WINDSOR, CT 06088-1020

Tel. (860) 627-5110FAX (860) 623-4477Internet http://www.dri-air.come-mail: [email protected]



CONTENTS

DESCRIPTION & FEATURES ------------------- 4

INSTALLATION PROCEDURE ------------------ 5Control Assembly-------------------------------- 5Receiver - Feed Throat ------------------------ 6Receaver - Hopper ------------------------------ 6Material Wand ------------------------------------ 7

ROUTINE OPERATION --------------------------- 8Air Pressure Adjustment ----------------------- 8Level Sensor Adjustment ---------------------- 8

ROUTINE MAINTENANCE ----------------------- 9

PARTS LIST -----------------------------------------10

ASSEMBLY DRAWING --------------------------- 11



The Dri-Air DAC Loader is a compressed air loaderpowered by your facility’s compressed air system. Itis capable of handling most materials, whether in vir-gin or regrind form. It is designed to transfer mate-rial from gaylords, storage bags or hoppers to mate-rial drying hoppers or mold press feed throats. Withan adequate source of compressed air, the loader iscapable of moving material a distance of 15 feet at arate of 125 lbs/hr.

Each loader package includes:

� Line-vac accelerator

� Two different length material wands

� Stainless steel receiver with level sensor andfilter

� Feed throat/hopper mounting adapter� Material hose

� Air line

� Electric control assembly with a regulator andmounting bracket.

Please see Assembly Drawing on page 11 for furtherdescriptions.

The loader controls are available in either 110 or 220volt configurations.

DESCRIPTION &FEATURES



Prior to installing the loader, make sure that all thecomponents listed in the previous section are in thepackage you received.

If the unit you are installing is a 220 volt model, aconnector compatible to your power distribution sys-tem will have to installed on to the power cord con-nected to the Control Assembly.

If the receiver is to be installed onto a hopper lid with-out a material retaining ring, the mounting adapterwill require an extension that protrudes into the hop-per to prevent overfilling of the hopper. This adaptercan be purchased from Dri-Air. Reference part #83926

When installing the loader, care must be taken toselect a location with a suitable electrical power sourcethat is as close as possible to the “hard piping” ofyour facility compressed air distribution system. Somehoses, pigtails and connectors can restrict the air-flow, decreasing the efficiency of the loader.

MOUNTING CONTROL ASSEMBLY

1. Using the mounting bracket supplied with the Con-trol Assembly, mount the assembly at a conve-nient location near the receiver that is accessibleto the operator. It must be within 8 feet of thereceiver so the sensor wires can reach and within6 feet of the electrical power source.

2. Connect the material conveying hose (1-¼”) to thereceiver and tighten the clamp.

3. Connect the Line-vac assembly to the other endof the hose and tighten the clamp. The materialhose must be connected to the “FLOW” port sideof the Line-vac. An arrow on the Line-vac indi-cates this port. The Line-vac assembly includesa wand or tube for pickup from out take-off-box ormaterial supply such as a bag or gaylord.

INSTALLATIONPROCEDURE

CONTROL INSTALLATION



4. Connect the black compressed air hose from thecontrol box assembly to the Line-vac. No toolsare required, just push the hose into the fittings.

5. Plug the sensor wire from the receiver into thecontrol box. Twist the plug after insertion to lock itinto place.

6. To connect the shop compressed air to the regu-lator on the control assembly, thread an appropri-ate quick disconnect nipple to the inlet port onthe regulator. The supply air must be at least 90psi using a ¼” airline.

MOUNTING RECEIVER: on a molding machine

1. The DAC loader is supplied with a 5.5”x5.5”(P/N 83668) square bottom flange mount-ing adapter. Drill the mounting flange tomatch the pattern on the machine feedthroat flange and bolt the mounting flangeto the machine.

2. Mount the receiver to the adapter by slip-ping it over the flange stub. Take note thatthe 2 O-rings in the mounting throat of thereceiver are in place.

MOUNTING RECEIVER: to load a hopper

1. Drill both the adapter flange and your hopper lidwith matching hole patterns. Bolt the adapter tothe hopper lid. CAUTION: Be sure that the hop-per lid is equipped with a material retaining ringthat prevents material from obstructing thehopper’s process air outlet port. If one is notpresent use an adapter that has an extension tubeon the base (Dri-Air part # 83926).

2. Mount the receiver on the adapter as detailedabove.

RECEIVERINSTALLATION



Material Wand Selection

Select the wand that fits the application for the loader.(The short takeoff box wand is designed to facilitatetransferring material from a hopper, while the longmaterial wand is designed to transfer material from astorage bag or gaylord.) Insert the Line-vac assem-bly into the wand and press until it fits snugly.

The unit is now ready for operation.



Material is conveyed using the facility compressedair that is accelerated by the Line-vac. The Line-vaccreates a vacuum at the tip of the wand to pull mate-rial into the hose and amplifies the air volume enter-ing the material hose to convey the material to thereceiver. The rate of material transfer can be ad-justed by regulating the air pressure. The higher thepressure setting on the regulator, the more materialthat will be conveyed. Air pressure can be adjustedby using the regulator on the Control Assembly.

Air Pressure Adjustment

Adjust the air pressure using the regulator onthe control assembly. Pull the adjustment knobup and turn the knob until the material con-veys at a proper rate. Too low a pressure willresult in not moving the material to the receiveror too long a fill time. If the pressure is toohigh, the material will not drop properly intothe receiver. When the proper pressure isachieved, push the knob down until you heara click. This locks the knob at it current set-ting.

The loader will transfer material to the receiver untilthe level sensor on the receiver is satisfied. The sen-sor signal will shut off the air supply and conveyingstops. The level sensor is factory adjusted, but dueto some operational conditions further adjustmentsmay be necessary. If the level sensor is out of ad-justment, follow the procedures detailed in the nextsection.

Level Sensor Adjustment

The sensor is adjusted at the factory for mostmaterials. If the unit does not load materialand the sensor light is not lit, turn the adjust-ment screw on the back of the sensor coun-terclockwise until the light is lit. If the loaderdoes not stop loading with material in front ofthe sensor, turn the adjustment screw (POT1)clockwise until the light goes out. The ad-justment screw has a 20-turn adjustment with

OPERATION



a slip clutch to prevent damaging the sensor.If the sensor is completely out of adjustment,turn the screw 20 turns counter clockwise toreach a home position. Then turn it clockwiseuntil the light goes out.

The DAC Loader is practically maintenance free. Theoperator need only perform the following proceduresto keep the unit operating efficiently.

Receiver Filter

Due to the dust in materials being transferred,the receiver filter will require a regular clean-ing, Simply remove the wing nut holding thefilter element to the top of the receiver and pullthe filter off. Remove the pre-filter and blowout the filter with compressed air. Perform thisat least monthly, sooner if material is very dusty.

Line-vac

Over time, contaminates from the compressedair source and the material being conveyed canplug the Line-vac’s small ports in the flow gen-erator, affecting the efficiency of the unit.Cleaning these ports will require the operatorto disassemble the Line-vac assembly. Re-move the hose and wand from the Line-vacand loosen the 3 button-head cap screws hold-ing the inlet port cap to the body. Separatethe cap from the body and remove the o-ring,flow generator and second o-ring. Clean theo-rings with water and wipe dry. Inspect andclean the flow generator ensuring that all theports are free from obstructions. If oils arepresent, wipe with a solvent and allow to dry.CAUTION: Do not put solvent on o-rings. Re-assemble the unit.

ROUTINE MAINTENANCE



Spare Parts List:

Part # Description

81546 Line Vac / Air Transvector82979 1-¼” Clear Hose w/Copper Ground Wire81055 Filter Element82995 Regulator82995A Regulator Gauge83031 (110 volt) Solenoid Valve83385 (220 volt) Solenoid Valve81180 Proximity Switch



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NOTES:

**Please Contact Dri-Air for any replacement parts for the loader.**

Operating instructions Capacitive sensors

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UK

2

Contents1 Preliminary note �� 32 Safety instructions �� 33 Functions and features �� 33�1 Application examples �� 44 Installation�� 44�1 Notes on flush and non-flush installation �� 44�2 Notes on installation in tanks �� 55 Electrical connection �� 55�1 Two-wire technology �� 66 Operating and display elements �� 67 Settings �� 77�1 Basic teach empty state�� 77�2 Adjustment teach full state �� 77�3 Modified basic teach empty state �� 87�4 Locking / unlocking �� 98 Operation �� 109 Maintenance, repair and disposal �� 1010 Technical data �� 10

3

UK

1 Preliminary note• Operating elements are indicated as follows:

Example: [OUT OFF] = pushbutton "OUT OFF“�• An instruction is indicated by "►":

Example: ► Mount the unit as shown�• A reaction to the action is indicated by ">":

Example: > Yellow LED lights�

Important note Non-compliance can result in malfunction or interference�

Information Supplementary note�

2 Safety instructions• Please read the operating instructions prior to set-up of the device� Ensure that

the product is suitable for your application without any restrictions�• The unit complies with the relevant regulations and EU directives�• Improper or non-intended use may lead to malfunctions of the unit or to

unwanted effects in your application�• Installation, electrical connection, set-up, operation and maintenance of the

unit must only be carried out by qualified personnel authorised by the machine operator�

3 Functions and features• Capacitive sensor for monitoring levels of liquids and dry bulk material,

preferably plastic granulates�• Automatic adjustment to the medium to be detected by means of programming

buttons�• The sensing face is rated for temperatures up to 110 °C and can be mounted in

direct contact with the sight glass (without air gap)�

4

3.1 Application examples

4 Installation4.1 Notes on flush and non-flush installationFor flush installation of non-flush units the sensor properties change and the sensor can remain permanently switched (loss of function)�

► Observe the free space around the sensing face�

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flush non flush

► Observe the minimum distances when mounting several sensors of the same type�

3x Sn ��

5

UK

4.2 Notes on installation in tanks ► Mount the unit as shown:

• In contact with the medium (only for non-metallic tanks) ► In case of liquids use a mounting adapter (e�g� E43900)�

• Not in contact with the medium (only for non-metallic tanks)

You can find mounting adapters at:www�ifm�com → Select your country → Data sheet search → Accessories

5 Electrical connectionThe unit must be connected by a qualified electrician�The national and international regulations for the installation of electrical equipment must be adhered to�

► Disconnect power ► Connect the unit

3x Sn

6

5.1 Two-wire technologyUse a miniature fuse according to the technical data sheet, if specified�

2

3

L1

N

L+

L

23

1: miniature fuse

Units in 2-wire technology:The unit is not short-circuit proof and not overload protected� Check the safe functioning of the unit after a short circuit� The unit is a class A product to CISPR 11� The unit may cause radio inter-ference in domestic areas� Therefore the user may have to take appropri-ate measures, if necessary�

6 Operating and display elements

1: LED ring yellow2: sensing face3: threaded sleeve4: programming buttons

7

UK

7 Settings7.1 Basic teach empty stateUsing the basic teach empty state the unit suppresses the installation environment� The basic teach empty state resets the unit, an adjustment teach already carried out is deleted�

► Empty the tank until the level is at least 20 mm below the sensor� ��

Set the unit as normally open (output closes when the tank is full):

► Press [OUT OFF] for min� 2 s (max� 6 s)� > While pressing the pushbutton the LED flashes

slowly� After releasing the pushbutton, the LED goes out�

2 - 6 s

Set the unit as normally closed (output opens when the tank is full):

► Press [OUT ON] for min� 2 s (max� 6 s)� > While pressing the pushbutton the LED flashes

slowly� After releasing the pushbutton, the LED lights continuously�

2 - 6 s

The unit is now ready for operation� For the detection of media with a low dielectric constant (e�g� plastic granulates or oils) no further setting is required�

7.2 Adjustment teach full stateNecessary for aqueous media� The sensitivity of the unit is optimised� Later on, the adjustment teach full state can be repeated at any time, an basic teach empty state already carried out is not affected�

8

A basic teach empty state must be carried out prior to the adjustment teach full state (→ chapter 7�1 Basic teach empty state)! If it is not possible to empty the tank, a basic teach empty state can be carried out by simulating the empty state (e�g� adjustment when not installed, adjustment at a higher position)� For optimum function it is necessary to carry out the "modified basic teach empty state" (→ chapter 7�3 Modified basic teach empty state) when the tank is emp-tied the next time�

► Fill the tank until the sensing face of the unit is covered�

> For NO the LED lights, for NC it goes out�


► Press [OUT ON] for min� 6 s� > While pressing the pushbutton the LED first flashes

slowly, after 6 s more quickly� After releasing the pushbutton, the LED lights continuously�

> 6 s


► Press [OUT OFF] for min� 6 s� > While pressing the pushbutton the LED first flashes

slowly, after 6 s more quickly� After releasing the pushbutton, the LED goes out�

> 6 s

7.3 Modified basic teach empty stateRecommended for deposits in the tank� Deposits are largely suppressed� This is also recommended if it has not been possible to carry out a basic teach empty state (e�g� if the sensor is set up on a full tank; details: → chapter 7�2 Adjustment teach full state)� Later on, the modified basic teach empty state can be repeated at any time, an adjustment teach full state already carried out is not affected�

9

UK

► Empty the tank until the level is below the sensing face of the unit�

> For NO the LED goes out, for NC the LED lights�


► Press [OUT OFF] for min� 6 s� > While pressing the pushbutton the LED first flashes

slowly, after 6 s more quickly� After releasing the pushbutton, the LED goes out�

> 6 s


► Press [OUT ON] for min� 6 s� > While pressing the pushbutton the LED first flashes

slowly, after 6 s more quickly� After releasing the pushbutton, the LED lights continuously�

> 6 s

7.4 Locking / unlockingThe unit can be electronically locked to protect it against unintentional setting�

► To lock press [OUT ON] and [OUT OFF] simultane-ously for 10 s�

> Acknowledgement: LED state (yellow) changes for a short time (the lit LED goes out briefly or the LED which is not lit lights briefly)�

► To unlock repeat this step�10 s

If the unit does not react, it may be locked�

10

8 OperationCheck whether the unit operates correctly� Bring about a sensor response by taking suitable measures�Display by LEDs (independent of the programmed output configuration);

LED yellow OUT: LED yellow ON:

switching output disabledswitching output enabled

9 Maintenance, repair and disposalThe operation of the unit is maintenance-free� For a correct function ensure:

► Keep the sensing face and a clear space, if any, free from deposits and foreign bodies�

When removing the unit or changing the medium, a new adjustment might be necessary�It is not possible to repair the unit�After use dispose of the unit in an environmentally friendly way in accordance with the applicable national regulations�

10 Technical dataTechnical data and further information at

www�ifm�com → Select your country → Data sheet search

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