Dosing Pump WB4000

Operating Manual

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Contents
1. 1. INTRODUCTION, FEATURES, AND ACCESSORIES: ................................................................ 3
1.1. ACCESSORIES .................................................................................................................................. 3
2. CONTROL SWITCHES AND INDICATORS ..................................................................................... 4
2.1. POWER ON/OFF ............................................................................................................................... 4
2.2. START/STOP ................................................................................................................................ 4
2.3. FORWARD/REVERSE ........................................................................................................................ 4
2.4. CALIBRATE ..................................................................................................................................... 5
2.4.1. Steps for calibration with injection mode:................................................................................... 5
2.4.2. Steps for calibration with extrusion mode:.................................................................................. 6
2.4.3. Steps for WB4000G: Gravimetric System.................................................................................... 7
2.5. SIGNALS....................................................................................................................................... 7
2.5.1. Injection..................................................................................................................................... 7
2.5.2. Extrusion / TRACKING.............................................................................................................. 8
2.6. REGRIND......................................................................................................................................... 8
2.7. ALARM ......................................................................................................................................... 8
2.8. BLUETOOTH................................................................................................................................ 8
2.9. LEDS AND FUNCTIONS .................................................................................................................... 8
3. STARTUP AND OPERATING PROCEDURES.................................................................................. 9
4. TROUBLESHOOTING ...................................................................................................................... 10
4.1. ERROR CODES ............................................................................................................................... 10
5. SPECIFICATIONS: ............................................................................................................................ 10
6. WARRANTY CONDITIONS.............................................................................................................. 12
7. 30. CUSTOMER SERVICE INFORMATION AND DISCLAIMER ................................................ 12

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 WARNING!
Do not remove cover!
No operator serviceable components inside.
To avoid electric shock refer servicing to qualified personnel!
Failure to follow the correct cable connection procedure will result in damage to the circuit
board, and voids the warranty!
Please check the labels on the WB4000 unit and read the manual before connecting any
cables.
1. 1. Introduction, Features, and Accessories:
The WB4000 controller consists of:
1. Controller box
2. Power, regrind and signal cables
3. Universal pump mounting flange
4. Motor coupling

The stepper motor and circuitry is combined into one compact self-contained ‘Drive Unit’.
Extras with the WB4000 unit are:
€ WiFi Router and CD
€ Handheld Unit

All set points are done via:

€ ComPacer software installed on an IBM compatible PC
€ ComPacer handheld PC software installed in a pocket PC handheld unit

ComPacer software supports up to 100 drive units.

Drive unit retains all set points, and runs at those settings, regardless if there is a connection
to a computer or a handheld or not.
Built-in communication capability of WB4000:
€ Wireless LAN via RF router
€ Bluetooth
€ LAN via RS485

Handheld unit, with security protocols, allows manual change capability at the drive unit
WB4000.
1.1. Accessories
A variety of accessories are availible with the WB4000 controller as kits:
Pump heads
€ Peristaltic pump heads from Masterflex
€ Eccentric screw with flange
€ Granulate feeder

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Handheld Kit
€ Pocket PC including charger
€ USB communication cable
WLAN Kit
€ RF Router
€ RF Router power supply
€ ComPacer Software CD
€ Cross-Over Ethernet Cable
Alarm-Kit
€ Warning Light
€ Cable
€ Mounting Post & Hardware Accessories
Extrusion Tracking Cable

2. Control Switches and Indicators

All the switches and LED's are located on the front panel except the main power ON/OFF
switch which is located on the side with the plug connections.
2.1. Power On/Off
On powering up, the unit will run through a self diagnostic routine and all LED's on the unit
will flash on the display until the unit finishes diagnostics. Once all the LED's stop flashing,
the STOP LED will light up, indicating that the controller is ready to run.
If the unit was running before power down then pressing START will resume operation with
the last settings stored in the controller.
To keep accurate material inventory, STOP the controller before powering down.
2.2. START/STOP
This allows the unit to begin operation. The previous information entered into the unit is as-
sumed to be the required settings once the START button is pushed and the START LED will
remain lit.
Searching for the best RFchannel is a secondary function for the STOP button when an RF
repeater has been installed. Hold TRACKDNG button while pressing POWER UP until
Communication LED is blinking. It takes app. 25 seconds for the unit to find the best RF
channel. The channel will be stored and there is no need for this procedure to be repeated.

2.3. Forward/Reverse
This allows the unit to be primed by manually pressing the FORWARD or REVERSE button.
Pressing the FORWARD button will light up the FORWARD LED and the controller is pro-
grammed to run at a fixed RPM for 1 minute or until the STOP button is pressed. For the Re-
verse mode the Reverse button must be held.

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2.4. Calibrate

This allows the unit to be calibrated automatically. In order to be able to calibrate, the unit
must be in STOP mode.
Once the pump has been primed and all the tubing is full (no air gaps) you can calibrate the
pump by collecting a sample weight.
For better accuracy, multiple samples should be taken and the average weight considered as
sample weight:

2.4.1. Steps for calibration with injection mode:

1. Start the program ComPacer (handheld computer).
2. Chose WB4000 Setup.
3. Press GET (handheld computer will get the current values from WB4000).
4. Check the mode: Injection or Extrusion.
5. Chose TIMER and fill in the approx. time needed for the feeding of the granulate.
6. Press shot size and fill in the weight of the moulded part.
7. Fill in the needed LDR in percent.
8. Chose UPLOAD (transfers the datas to the WB4000).
9. Chose OPTIONS.
10. Chose CALIBRATE.
11. Option: By pressing the checkbox, a special speed (RPM) can be preset. With this
RPM the calibration will be started.
12. Chose the counts for calibration run, check the dosing time.
13. Chose NEXT. The target weight will be shown.
14. Press the button CALIBRATE at the WB4000.
15. CALIBRATE LED will be lit and START LED will flash.
16. Place a container under the outlet tube.
17. After pressing the START button, the LED CALIBRATE will flash, and the motor will
run for a preset time at a preset RPM.
18. When the motor stops running, weigh the sample collected and enter this value in the
Sample Weight field in the handheld ComPacer software. Chose NEXT to transfer the
datas to the WB4000 unit.
19. Chose DONE to end the calibration run or REPEAT to repeat steps 12 to 19.
The calibration can be made with the ComPacer software via PC or with the ComPacer soft-
ware via handheld PC.

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2.4.2. Steps for calibration with extrusion mode:
1. Start the program ComPacer (handheld computer).
2. Chose WB4000 Setup.
3. Press GET (handheld will get the current values from WB4000).
4. Check the mode: Injection or Extrusion.
5. In case of setting:”kg/hr“: Chose Prod Rate/hr and fill in the amount of the product
produced within one hour.
Alternative setting “m/hr“: In the field “m/min“ fill in the meter produced within a minute
and in the field “g/m“ fill in the weight of one meter of the product.
6. Fill in the needed LDR in percent.
7. Chose OPTIONS.
8. Chose CALIBRATE.
9. Option: By pressing the checkbox a special speed (RPM) can be preset. With this
RPM the calibration will be started. Check the dosing time.
10. Chose NEXT. The target weight will be shown.
11. Press the button CALIBRATE at the WB4000.
12. CALIBRATE LED will be lit and START LED will flash.
13. Place a container under the outlet tube.
14. After pressing the START button the LED CALIBRATE will flash, and the motor will
run for a preset time at a preset RPM.
15. When the motor stops running, weigh the sample collected and enter this value in the
Sample Weight field in the handheld ComPacer software. Chose NEXT to transfer the
datas to the WB4000 unit.
16. Chose DONE to end the calibration run or REPEAT to repeat steps 9 to 16.

The calibration can be made with the ComPacer Software via PC or with the ComPacer
Software via handheld.

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2.4.3. Steps for WB4000G: Gravimetric System

1. Connect the scale with the WB4000 unit.

2. Start the program ComPacer (handheld PC).
3. Chose WB4000 Setup.
4. Chose GRAVIMETRIC.
5. Press GET (handheld PC will get the current values from WB4000).
6. Mode: Injection:
Chose TIMER and fill in the approx. time needed for the feeding of the granulate.
Press shot size and fill in the weight of the molded part.
Fill in the needed LDR in percent.
7. Modus: Extrusion:
In case of setting: “kg/hr“: Chose Prod Rate/hr and fill in the amount of the product
produced within one hour.
Alternative setting “m/hr“: In the field “m/min“ fill in the meter produced within a minute
and in the field “g/m“ fill in the weight of one meter of the product.
Fill in the needed LDR in percent.
8. Chose UPLOAD (transfers the datas to the WB4000).
9. Chose OPTIONS.
10. Chose CALIBRATE.
11. Press the button CALIBRATE at the WB4000.
12. CALIBRATE LED will be lit and START-LED will flash.
13. Place a container under the outlet tube.
14. After pressing the START button the LED CALIBRATE will flash, and the motor will
run for a preset time at a preset RPM. The WB4000 will calibrate itself by running a
cycle of 10 shots. After that the calibration is done.
During the process the dosed amount will be measured and constantly adjusted.

2.5. SIGNALS
2.5.1. Injection
In case of the mode Injection the screw recovery signal for the injection molding machine will
be needed. The following inputs can be used: “DRY CONTACT“(cable colors black/green) or
voltage signal (22-240VAC/DC). In mode TIMER the WB4000 will run after getting the signal
for the preset time. In mode SIGNAL the WB4000 will run as long as the unit will get the sig-
nal. In this mode the WB4000 will measure the time and will react depending on the last cy-
cle.

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 2.5.2. Extrusion / TRACKING
In case of mode Extrusion a signal from the running extruder is required. The following inputs
can be used: “DRY CONTACT“ (cable color black/green) or with voltage signal (22-
240VAC/DC).
Using the tracking function allows the unit to follow the extrusion signal an increase or de-
crease the speed in relation to the extruder speed. The input signal selected when the
TRACK button is pressed is assumed to be the required speed. The signal can be: voltage 0-
10 V (serial cable color black/white) or amperage 4-20mA (serial cable color black/red).
When the extruder is running stable and the WB4000 is calibrated, the tracking will be
started by pressing the TRACKING button. The Tracking LED will light up.
2.6. Regrind
The unit will make a compensation for regrind based upon the % entered. The default setting
is 0%. When a regrind signal is received, the unit will subtract the amount of regrind from the
total and re-adjust the pumping rate. This applies to extrusion or injection. The regrind signal
input is either DRY CONTACT (cable color red/white) or the voltage signal 24 – 240 V.
2.7. ALARM
When the container weight is lower than the preset Low Level Weight, Low Level Alarm LED
will light up and 48 V will be applied to the alarm output. Please be advised that maximum
current output is100mA
2.8. BLUETOOTH
To enable/disable Bluetooth communication with the handheld device:

€ Make sure that the availability is activated and the setup for the serial connection is
activated. It is necessary that the checkbox “password needed” is not activated. The-
se settings can be done in the Bluetooth manager.
€ Press LINK button

The Bluetooth LED will flash while WB4000 controller is searching for the handheld unit!
When communication between these two devices is established, the Bluetooth LED will light
up:
2.9. LEDs and functions
The front panel consists of the following visual LED indicators:

€ Communication LED - When RF communication is established this will light up.

€ Motor LED - When stepper motor is running this will light up.
€ Signal LED - When injection signal is detected this will light up.
€ Regrind LED - When regrind signal is detected this will light up.
€ Injection LED - When unit is operating in the injection mode this will light up.
€ Extrusion LED - When unit is operating in the extrusion mode this will light up.
€ Bluetooth LED - When unit is connected to the handheld device this will light up.
€ Low Level LED - When the container weight is lower than the preset Low Level
Weight, this will flash. Please be advised that Low Level Weight is accurate if the
calibration procedure is done according to specifications.
€ Error LED - When the unit is operating outside maximum or minimum speed
this will be flash. Motor – shows motor is running

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3. Startup and Operating Procedures
1. Install the required pump and tubing.
2. Connect the signal cable to the injection or extrusion machine. For injection moulding
this is typically the screw recovery signal. For extrusion applications this is a continu-
ous power supply from the extruder that is on when the extruder is running and off
when the extruder is stopped; (24-120 VAC/DC) or “DRY CONTACT“ (Cable colors
black/green).
3. If required for extrusion applications, connect the extrusion tracking cable.
Voltage 0-10 V (serial cable color black/white) or amperage 4-20mA (serial cable
color black/red).
4. If required, connect the regrind signal cable to the controller. (24-120 VAC/DC) or
DRY CONTACT (cable color red/white).
5. Connect the controller to power supply; this can be 110 VAC / 220 VAC, 50/60 Hz.
Refer to power input label.
6. Turn on the main power switch and the controller will go through a diagnostics pro-
gram. Once diagnostics is complete the STOP LED will light up.
7. Press the FORWARD key to prime the pump.
8. Once the pump has been primed and all the pump tubing is full of product you can
calibrate the pump output by collecting a sample weight. See page 5 – 2.4 Calibrate
procedure.
9. Using either the handheld unit or the ComPacer software:
€ GET data from the WB4000 unit
€ Select the Mode of Operation: Injection or Extrusion
€ Input the LDR %
€ Input the shot size for injection or throughput for extrusion mode
€ Input the shot weight
€ Input regrind % (if required)
€ UPLOAD data in the WB4000 unit. This information will automatically be trans-
ferred into the controller which will calculate the counts (Injection Mode) or RPM
(Extrusion Mode) required.
10. Press the START key and the controller will begin to function with the preset settings.

As a safety feature, the mode of operation (injection or extrusion) cannot be changed while
the WB4000 unit is running. In order of changing the mode of operation the WB4000 unit
must be stopped first.
Errors encountered by the controller will be transferred to the ComPacer and handheld de-
vice for readout on the screen. If the speed of the stepper motor exceeds either the upper or
lower limit the unit will continue to operate at the limit and send out an error message.

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4. Troubleshooting
4.1. Error codes
1. If the required speed exceeds the maximum capability of the stepper motor then the
ERROR LED will flash rapidly on the unit. In ComPacer software a descriptive (Speed
111) error message will be displayed on the monitor screen. The unit will continue to
operate at its maximum output. Please correct by adjusting the tubing and/or parame-
ters.
2. If the required speed is less than the minimum capability of the stepper motor then
the ERROR LED will flash slowly on the unit. In ComPacer software a descriptive
(Speed LOW) error message will be displayed on the monitor screen. The unit will
continue to operate at its minimum output. Please correct by adjusting the tubing
and/or parameters.
3. If the internal self diagnostics have failed during power up, the ERROR LED will con-
tinue flashing.
5. Specifications:
€ Stepper motor drive for precise color metering
€ Pumping rate from 0.7 to 120 RPM
€ Injection mode
€ Extrusion tracking mode, 0-10 VDC or 4-20 mA
€ Automatic adjustment for injection cycle recovery time variations
€ Automatic adjustment of output based upon percentage of regrind
€ Automatic calibration
€ Automatic storage of settings during power down
€ Non volatile EEPROM storage of settings
€ Non volatile EEPROM storage of material inventory up to 200 t
€ Built-in separate signal timer
€ Electrical power input of 120 or 220 VAC, 50 or 60 Hz.
€ Dimensions, Height 6", Width 6", depth 12"
€ Weight 20 pounds
€ Two year warranty on hardware
€ Wireless data acquisition/control
€ RS485 hardwire ports
€ Bluetooth

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Switches & LEDs:
Switches
€ Power on
€ Start
€ Stop
€ Forward
€ Reverse
€ Tracking
€ Calibrate
LED's
€ Communication
€ Motor
€ Signal
€ Regrind Signal
€ Injection Mode
€ Extrusion Mode
€ Bluetooth
€ Low Level
€ ERROR
Side Plugs:
€ Power cable (110 or 220 VAC, 50/60 11z)
€ ON/OFF circuit breaker (1.5A/120VAC; 0.8A/220VAC)
€ Signal cable (24-120 VDC/VAC)
€ Regrind (24-120 VAC/DC)
€ Alarm/Warning light (48 VDC max. 100 mA load)
€ Tracking (0-10 VDC or 4-20 mA) extrusion tracking
€ RS 485 In / RS 485 Out

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6. Warranty conditions
1. For a period of two years from the supply date Novosystems GmbH, Germany, provides
a warranty for manufacturing and product defects.
2. During the warranty period, Novosystems will repair any faults or defects arising from
production or component defects free of charge. The device must be returned to Novo-
systems, carriage-free, for this purpose. When the repair has been completed, the device
will be returned carriage-free to the customer. Novosystems may decide to repair or re-
place the device or to refund the purchase amount, at its discretion. If repair work has to
be done locally, travel, overnight accommodation costs and associated expenses will be
invoiced separately.
3. The warranty expressly excludes any further claims based on consequential damage
such as loss of production, loss of profits etc.
4. Any malfunctions or consequential damage caused by inappropriate use and/or handling,
overloading, use in breach of the instructions given in the manual, or acts of violence are
excluded from the warranty.
5. The warranty does not cover damage in transit. Customers are advised to take out suffi-
cient transport insurance cover before shipment.
6. The warranty shall cease to apply if any modifications have been made to the device
supplied by Novosystems and/or if the quality seal has been damaged.

7. 30.Customer Service Information and disclaimer

Free training seminars are provided for selected management and operating personnel, cov-
ering all aspects of the use and applications of NOVOCOLOR®.
The training courses are provided at the customer's premises under normal working condi-
tions, to ensure that the use of NOVOCOLOR® and NOVOSYSTEMS® metering pumps can
be demonstrated and learned in a realistic operating environment.
After the successful completion of the introductory phase, qualified technicians and engi-
neers from NOVOSYSTEMS® will continue to be available for assistance at any time.
Any further training seminars required can easily be arranged.

NOVOSYSTEMS® believes in offering high quality customer service and delivering solutions
to meet its customers' needs.

The information and advice in this brochure is given to the best of our knowledge at this time,
and should be used by the customer to check that the product is suitable for the specific pur-
poses for which it is intended. The information provided cannot become the basis for any
liability claims against NOVOSYSTEMS® Farben und Additive GmbH and its related firms
and sub-contractors, including any claims relating to third party rights.
NOVOSYSTEMS
Farben und Additive GmbH
Winsener Landstr. 124
D-21217 Seevetal/Fleestedt
Germany
Tel.: +49 (0)4105-1458-0
info@novosystems.de
www.novosystems.de

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