Dosing Control

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
Version 0 3 . 0 0 A
Version 1 2 . 9 9 A
Version 0 3 . 0 0 A
Version 0 3 . 0 0 A
Version 1 2 . 9 9 A
Version 1 2 . 9 9 A
Version 0 3 . 0 0 A
Version 1 2 . 9 9 A
Version 0 3 . 0 0 A
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 A
Version 0 3 . 0 0 A
Version 1 2 . 9 9 A
Version 0 3 . 0 0 B
Version 0 3 . 0 0 A
Version 0 3 . 0 0 A
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
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 1 2 . 9 9 A
Version 1 2 . 9 9 B
Version 0 3 . 0 0 B
Version 1 2 . 9 9 A
Version 1 2 . 9 9 A
Version 0 3 . 0 0 B
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
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 A
Version 0 3 . 0 0 A
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
Version 0 3 . 0 0 B
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

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
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

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
if no entry of a dosing volume has been made
P r o D o s
03.03.00
INFO
F1

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

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
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:
Segmented display of the actual and desired melt

temperature:
Back-lit display:
HARDWARE

01.01
2-2
0101-A.doc
blank page
Version: 12.99 A

OPERATING MANUAL
DOSING CONTROL
HARDWARE
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
01011-B.doc
Version: 03.00 A
1-4
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 100/35mm 13:34:57
EXT-KEY DOS-ON or F5 = DOSING
!

P r o D o s
03.03.00
INFO
F1

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

OPERATING MANUAL
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.
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
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.
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
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
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

OPERATING MANUAL
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
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
TEMPERATURE DISPLAY
01.01.2
2-2
01012-B.doc
blank page
Version: 03.00 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
HARDWARE
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

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

- Display and delete total and shift cycle counter
of injections and errors
- see chapter 06.03
Key
DATA DISPLAY
to activate

- 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
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

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
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

OPERATING MANUAL

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
02.00
The P ro D os DPC WESTOMAT control is equipped

with a range of programme options.
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.

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 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

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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

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

0
2.5
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
- 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.

- 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

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
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

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

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:
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):
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
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
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).

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
t6
t7
DCM-DIE
TS=
DC
t2
t3
t4
t5

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
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

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

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
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

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

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
DOSING
02011-A.doc
Version: 12.99 A
1-4
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

+0.30
-0.25
-28.0
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
DOSING

02.01.1
2-4
02011-A.doc
AUTO-INCREASE (cont.)

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

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 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

value as it is related to the nominal % value.
Version: 12.99 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
DOSING

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.

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.
DOSING

02.01.1
4-4
02011-A.doc
blank page
Version: 12.99 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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
!
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.

P r o D o s
03.03.00
INFO

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

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

80 /24 NO 1 = DOSING PIPE
INFO
10.03.00 HEATING
OFFLINE: kg-DOS-NEW
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
kg-DOS-RANGE:
2.50 to 7.35 kg
3.55
kg = dosing volume (OFFLINE)
+0.00
0.00
28.0
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.
DOSING

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:

OPERATING MANUAL
5.70
2.50 to 7.35 kg
- 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
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
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
DOSING
WESTOMAT ProDos DPC

OPERATING MANUAL

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
the LED of the MEMO key is blinking (ready to

save):

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

MODIFY
INFO
DATA
DOSING
multi-function key
F1
F2
F3
F4
F5
F3
= MODIFY DATA or
DOSING

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

OPERATING MANUAL
DOSING CONTROL
OFFLINE:
5.60kg
AUTO
DOSING
SCAN=CELL ... ON
DOS. PIPE: 65/21mm
kg-DOS-RANGE:
4.53 to 6.67 kg
5.60
+0.00
-0.30
28.0
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
- 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
- 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
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
DOSING
WESTOMAT ProDos DPC

OPERATING MANUAL

02012-B.doc
DOSING CONTROL
Version: 03.00 A
5-6
OFFLINE:
5.60kg
AUTO
DOSING
SCAN=CELL ... ON
DOS. PIPE: 65/21mm
After entry and pressing of key


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:
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

MODIFY
INFO
DATA
DOSING
The entry of a NEW kg-DOS-VOLUME file is now

completed.
DOSING

02.01.2
6-6
02012-B.doc
blank page
Version: 03.00 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
0202-A.doc
Version: 12.99 A
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.

OPERATING MANUAL

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
t6
t7
DCM-DIE
TS=
DC
t2
t3
t4
t5

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

0202-A.doc
Version: 12.99 A
OFFLINE:
5.75kg
MANUAL
DOSING
SCAN=CELL ... END
DOS. PIPE: 80/24mm
- Set DCM into AUTO !
- 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:

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

MANUAL DOSING .. END..
AUTO DOSING .. ON .........
O-09
from WESTOMAT
to DCM:
O-10
O-11 + 12
O-14
ATTENTION
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.

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
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.
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

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).

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

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:

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

is started.
ATTENTION
STATUS to DOSING MODE, the switching status I20 / 21 = 0 is checked and, if incorrect, position
error I-20 / 21 = 1 is signalled.
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.

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
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.

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

0202-A.doc
Version: 12.99 A
7 / 12
02.02
PLUNGER IN BACK POSITION ................... I-24

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
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

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).
0202-A.doc
8 / 12
02.02
DISCONT. SYNCHRO. OPERATION (OPT.) I-25

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

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

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

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.
automatically at the program stage DOSING

END

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

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

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

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

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.
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.

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.

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

DOSING CONTACT ..............
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

DOSING CONTACT .............
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

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

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
0203-B.doc
Version: 03.00 B
1/4
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.

OPERATING MANUAL

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 %
46 %
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
HEATING
SCAN=CELL
!

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

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

MODIFY
INFO
DATA
DOSING
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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

02.03
4/4
0203-B.doc
blank page
Version: 03.00 B

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
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
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.

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
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 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
!
The selection of a specific operating mode is carried

out in the BASIC STATUS of the Pro Dos DPC.

P r o D o s
03.03.00
INFO

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
Press multi-function key
F3
= OPERATING
MODES
F1
F2
F3
F4
F5
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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).

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
******
= ENTRY CODE-N and ENTER
10.03.00
SETUP MODE:
SCAN=CELL
CELL-FILLING-INDIC. 13:34:57
The display form with instructions appears

Press

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
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
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
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.

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
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

MODIFY
INFO
DATA
DOSING
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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.

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
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)

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
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.

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
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.
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

OPERATING MANUAL
OPERATING MODES
02.05
12 / 12
0205-B.doc
blank page
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

OPERATING MANUAL
STRUCTURE OF THE OPERATOR INTERFACE

2 - 14
03.00
0300-A1.DOC
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

0300-A1.DOC
Version: 12.99 A
3 - 14
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

4 - 14
03.00
0300-A1.DOC
Version: 12.99 A

OPERATING MANUAL
DOSING CONTROL
FUNCTION KEY: F3 = OPERATING MODES

ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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

0300-A1.DOC
Version: 12.99 A
5 - 14
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

ALWAYS
COMPLY
WITH
SAFETY
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

6 - 14
03.00
0300-A1.DOC

OPERATING MANUAL
Version: 12.99 A
SETUP MODE: LOG DATA

ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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

0300-A1.DOC
Version: 12.99 A
7 - 14
03.00
SETUP MODE: FILLING LEVEL

INDICATION (CELL)
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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:
levels can be selected by the operator.
OPERATOR INTERFACE

OPERATING MANUAL

0300-A1.DOC
8 - 14
03.00
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

0300-A1.DOC
Version: 12.99 A
9 - 14
03.00
SETUP MODE = FILLING LEVEL

INDICATION (HPDE)
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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:
levels are preset in the software
SELECTABLE VALUES:
levels can be selected by the operator
.
OPERATOR INTERFACE

OPERATING MANUAL

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

0300-A1.DOC
Version: 12.99 A
11 - 14
03.00
SETUP MODE: kg - DIAGRAM

ATTENTION

ALWAYS
COMPLY
WITH
SAFETY

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

0300-A1.DOC
12 - 14
03.00
Version: 12.99 A

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

0300-A1.DOC
Version: 12.99 A
13 - 14
03.00
SETUP MODE: REGULATOR HEATING

ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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

0300-A1.DOC
14 - 14
03.00

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
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

0
2.5
and multi-function ke
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
= 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
Press help key
i/T
to activate INFO display and compare displayed

values with the die-specific settings.
ESC .

OPERATING MANUAL

04.00
0400-B.doc
2-6
Version: 03.00 A
TESTING:
- Operating mode: TOP-STOP
- Operating mode: SYNCHRONIZATION
- see also chapter 02.05.
***BASIC STATUS***
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE 80/24mm
,
INPUT,
ENTER
and
MEMO / ESC=back

F3 =
OPERATING MODES, enter settings for:
with TOP-STOP = 1
SYNCHRONIZATION
CLOSED = 1
SETUP OPERATING MODES

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

DIE CLOSED 1
YES=1 N0=0
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
!

P r o D o s
03.03.00
INFO
DOSING CONTROL
TESTING:
- Dosing volume
- see also chapter 02.01.1.
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
In BASIC STATUS of the Pro Dos DPC

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
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

+ 0.00
-0.45
-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

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
!
***** 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.
03.03.00
INFO

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
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
After rectifying of all ERRORS / POSITION

ERRORS, the dosing operation must be continued.
Instruction for AUTO-DOSING OPERATION:

- switch DCM into AUTO!
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.

OPERATING MANUAL

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
MODIFY
INFO
DATA
DOSING
OFFLINE:
5.75kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 80/24mm
- this operational mode is not
selected
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

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
t6
t7
DCM-DIE
TS=
DC
t2
t3
t4
t5

INFO
MODIFY
DOSING
DATA
by HAND
WESTOMAT ProDos DPC

OPERATING MANUAL

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

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
MANUAL POSITION!
OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 80/24mm
t6
t7
The DCM DIE is fully closed

- Ready for operation for MANUAL-DOS
DCM-DIE
DC
t2
t3
t4
t5

INFO
MODIFY
DATA
DOSING
by HAND
OFFLINE:
5.75kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 80/24mm
I-24 PLUNGER IN BACK POSITION (DCM) ....
= 1
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.

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

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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
!

P r o D o s
03.03.00
INFO

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,
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
Display changes to F5-STATUS displaying the

instruction form for DOSING

completely !
MODIFY
kg-DOS:
INFO
DATA
NEW
DOSING
OFFLINE:
27.65kg
10.03.00 HEATING
13:34:57 CELL IND.
DOS. PIPE: 100/35mm
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
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
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
MANUAL POSITION!
INFO
MODIFY
kg-DOS:
DATA
NEW
DOSING

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
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:
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
MODIFY
INFO
DATA
DOSING
OFFLINE:
27.65kg
MANUAL
DOSING
CELL IND. ... ON
DOS. PIPE: 100/24mm
t6
t7
DCM-DIE
F5
- Dosing process see chapter 02.01.
TS=
DC
t2
t3
t4
t5

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
t6
F5
F2
t7
DCM-DIE
- Dosing process see chapter 02.01.

DC
t2
t3
t4
t5
To SWITCH OFF dosing operation:
INFO
Press key ESC - back to BASIC STATUS, or

press external key
F5-STATUS and
MODIFY
DATA
DOS-OFF to return to
F1
F2
F3
DOSING
by HAND
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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:
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
After starting in MANUAL-DOS by means of:

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

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.
SWITCHING AUTO-DOS ON / OFF

04.02
2-2
0402-A.doc
blank page
Version: 12.99 A

DOSING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
DISTURBANCES
0500-B.doc
Version: 03.00 A
1-6
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

OPERATING MANUAL
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:

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
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!
DIST.
DOSING
ACKNO.
DISTURBANCES
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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
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:

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
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:

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:

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.-07: PneuCo
DISTURB.-08: DOSING CONTACT
DISTURB.-09: UNDERTEMPERATURE
Version: 03.00 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
DISTURBANCES
0500-B.doc
Version: 03.00 A
5-6
05.00
... STATUS DISTURBANCES (continued)

DISTURB.-11: 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.-37: DOSING OFF
DISTURB.-38: TOP-STOP
DISTURB.-39: TOO MUCH LEAKING LOSSES
DISTURB.-41: OPERATION LEVEL EMPTY
DISTURBANCES
05.00
6-6
0500-B.doc
... WESTOMAT PROCESS DISTURBANCES (cont.)

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.-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.-70: DISCONT. SYNCHRO OPERAT.
DISTURB.-71: DCM-DIE READY F.INJECT.1 = 0
Version: 03.00 A

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

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
4 mA or I > 20 mA:
Inspect furnace chamber measuring pressure

converter and circuit and repair, if necessary
DISTURBANCE 03: LOAD CELL

the disturbance results from the monitoring of the
4 mA or I > 20 mA:
The filling level lamps start to blink
Inspect load cell (CELL) and circuit and repair, if

necessary
DISTURB.-02: MEAS. PRESS. CONVERTER

DIST. of signal MEASURING-PRESSURE CONV:
- mA-Signal of AI-03 too SMALL
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURB.-03: LOAD CELL

DIST. of signal LOAD CELL (SCAN):
- mA-Signal of AI-04 too SMALL
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
DISTURBANCES
STATUS DISTURBANCES
0501-B.doc
Version: 03.00 B

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
DIST. of signal EMERGENCY STOP WESTOMAT:

- within WESTOMAT range, EMERGENCY STOP
key is used (I-02 = 0)
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
Disturbance with termination of dosing process

Inspect filling level in furnace and refill, if
necessary
DISTURBANCE 05: EMERGENCY STOP

WESTOMAT
switch status of I-02 = 1, if I-02 = from 1 to 0:

DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
After evaluation of the cause for the

EMERGENCY STOP, unlock the EMERGENCY
STOP key of the WESTOMAT control
DISTURBANCE 06: EMERGENCY STOP DCM

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)
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
05.01
DISTURBANCE 04: FURNACE EMPTY

with CELL
DISTURB.-04: FURNACE EMPTY
3-6
DISTURBANCE 07: PneuCo

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)
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCES
STATUS DISTURBANCES
05.01
4-6
0501-B.doc
DISTURBANCE 08: DOSING CONTACT

In DOSING ... RUN not monitored

Inspect dosing contact monitoring system
(PneuCo or ELECTRODE) and repair, if
necessary
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
DISTURB.- 08: DOSING CONTACT

Disturbance of signal DOSING CONTACT
(DC):
- permanent contact within area of (DC)
dosing contact detection (I-01 = 1)
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:
DISTURBANCE UNDERTEMPERATURE MELT:

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 !

DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCE 10: UNDERTEMPERATURE
With external regulator:


DISTURBANCE UNDERTEMPERATURE MELT:

- external regulator signals undertemperature melt (I-04 = 0)
- check and WARM-UP !
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
The disturbance results from the monitoring of a

limit value of the melt temperature, if XC > WC
+ C-OVERTEMPERATURE-MELT:
The furnace heating heats the melt to a

temperature above the min. temperature and I04 = from 0 to 1
DISTURBANCE 11: OVERTEMPERATURE

Wait until melt has reached a temperature
below the max. temperature (furnace heating =
OFF)
DISTURBANCE OVERTEMPERATURE MELT:
signal (AI-01) has exceeded the temp.
limiting value MAXIMUM
- check and let melt COOL !
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCES
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
STATUS DISTURBANCES
0501-B.doc
Version: 03.00 B
5-6
05.01
DISTURBANCE 12: OVERTEMPERATURE

With external regulator:
DISTURBANCE OVERTEMPERATURE MELT:

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

Wait until melt has reached a temperature

below the max. temperature (furnace heating =
OFF)
- check and let melt COOL !

DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCE 13: CLEANING DOOR
DISTURB.-13: CLEANING DOOR

DISTURBANCE of signal CLEANING DOOR:
- lim-switch of cleaning door (I-06=0)
signalize NOT CLOSED
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW

Close the open solenoid lock of the cleaning

door (or repair, if damaged)
DISTURBANCE 14: OVERPRESSURE FURNACE

CHAMBER
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

DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURBANCE 15: CAST POSITION

Check the limit switch operation (repair, if

damaged)
DISTURB.-15: CAST POSITION

DIST. of signal FURNACE IN CAST POS:
- (I-09=0) lim-switch FURNACE in CASTPOSITION not activated
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCES

OPERATING MANUAL
STATUS DISTURBANCES
6-6
05.01
0501-B.doc
DISTURBANCE 16: HEATING ON


Evaluate the cause for the switching off of the

furnace heating and switch on heating
Version: 03.00 B
DOSING CONTROL
DISTURB.- 16 HEATING ON
Disturbance of signal HEATING ON:
- circuit for HEATING ON (I-15 = 0)
is not active
check and switch on !
DIST.
MODIFY
kg-DOS:
DOSING
ACKNO.
DATA
NEW
DISTURBANCE 17: TEMPERATURE FURNACE

CHAMBER
max. value of the AL3 furnace chamber
temperature, if the furnace chamber temperature
(AI-02) exceeds this limit value:

Evaluate the cause for the disturbance

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

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

P r o D o s
03.03.00
INFO

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
trained staff.
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:
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.
DISTURBANCE 31: DOSING

CONTACT NOT REALIZED
the monitoring of the switch status I-01 = from 0 to
1 of the DC, if:

- 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
insufficient contact of the electrode with the

+ 24 V DC voltage
electrode not in scanning position
metal feed already carried out.
DISTURBANCES

2-8
05.02
0502-B.doc
Version: 03.00 A
DISTURBANCE 32: DOSING CONTACT NOT BACK

In DOSING ... RUN with electrode DC monitoring,
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
DOSING CONTROL
DISTURB.-32: DOSING CONTACT NOT BACK

- 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:

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,
switch status I-01 = 1, if:
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 dosing pipe for clogging and
remove clogging!
failure of PneuCo
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURBANCE 34: ADDITIONAL DOSING

CONTACT
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

cylinder
of
the
electrode
in
DISTURB.-34: ADD. DC=DOSING CONTACT

- DC has been repeatedly switched during
metal feed
remove fault!
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURBANCES
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

0502-B.doc

- DC has been repeatedly switched after
deaeration
- OPEN DIE and
- ADVANCE PLUNGER !
Version: 03.00 A
END
- 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!

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.
malfunction of in the furnace chamber

aeration

cylinder
kg-DOS:
DOSING
NEW
DISTURBANCE 36: DOSING CONTACT AFTER

- DC has not been switched after
deaeration
END
In DOSING ... RUN with PneuCo DC monitoring,
- remove deposits on dosing pipe !

- check furnace-chamber deaeration and
remove fault!
- check log time value of t5-DC (K02)
and modify if necessary !
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.
failure of PneuCo
kg-DOS:
DOSING
NEW
DISTURBANCE 37: DOSING OFF
DISTURB.-37: DOSING OFF

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.
inadvertent activation of the DOS-OFF key
DISTURBANCES

4-8
05.02
0502-B.doc
Version: 03.00 A
DISTURBANCE 38: TOP-STOP

OPERATING MANUAL
DOSING CONTROL
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
(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:

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)
- 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)

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
- 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

0502-B.doc

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
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
Repeat refilling until FURNACE FULL.
DISTURBANCE 42: OVERPRESSURE FURNACE

CHAMBER
DISTURB.-42: OVERPRESS. FURNACE CHAMBER

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

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

- 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
(replace
if
kg-DOS:
DOSING
NEW
DISTURBANCE 43: FEED PRESSURE TOO HIGH
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!
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW

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
(replace
if
DISTURBANCES

6-8
05.02
0502-B.doc
Version: 03.00 A
DISTURBANCE 44: FEED PRESSURE TOO LOW

the monitoring of the feed pressure, if:
The feed pressure does not reach the

calculated limit value. Evaluate cause and
failure of
damaged)
leak losses at the furnace body or the

aeration valves
the
prop.
valve
(replace

OPERATING MANUAL
DOSING CONTROL
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!
- OPEN DIE and
- ADVANCE PLUNGER !
if
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
lack of pressure in pressure air line
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:
the measured value for the furnace chamber

pressure is too low. Evaluate cause and rectify.
DISTURB.-45: DC-PRESSURE TOO LOW
(incorrectly (too low) positioned scanning

electrode

and DC-detection, remove fault
value entered in LOG K06 for max. melt

level difference is too high
DIST.
ACKNO.
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.
blocked feed channel in dosing pipe

value entered in LOG K06 for max. melt
level difference is too high
DISTURBANCE due to high pressure at the

time of DC-dosing contact:
and DC-detection, remove fault
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURBANCES
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL

0502-B.doc
DISTURB.-47: DEAERATION FURNACE

Furnace deaering was performed too late
or too slow:
- check deaering valve !
- 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
kg-DOS:
DOSING
NEW
deaeration valve opens too late or not

properly
DISTURBANCE 48: TOTAL FEED TIME
DISTURB.-48: TOTAL DOSING TIME

DISTURBANCE - aggregate dosingtime was
too long (t3 + t4):
- OPEN DIE and ADVANCE PLUNGER
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW

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

If the disturbance persists, please contact
StrikoWestofen service department.
DISTURBANCES

05.02
8-8
0502-B.doc
blank page
Version: 03.00 A

OPERATING MANUAL
DOSING CONTROL
DISTURBANCES
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
0503-B.doc
Version: 03.00 A
1-6
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
trained staff.
operating manual.
DISTURBANCE 60: AUTO-OPERATION DCM
DISTURB.-60: AUTO-OPERATION DCM

DISTURBANCE due to DCM-signal I-18:
- signal has not been switched from 1
to 0 during dosing mode
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
In AUTO-DOS RUN, the disturbance results from

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

cause and rectify. Possible causes are:
DISTURBANCES

OPERATING MANUAL

2-6
05.03
0503-B.doc
DISTURBANCE 61: DCM-DIE CLOSES
Version: 03.00 A
DOSING CONTROL

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.
Evaluate causes for the switching I-19 = from 1

to 0. Possible causes are:
- 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

the monitoring of the switch status I-20 / 21 = 1, if:
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.

during dosing mode
Evaluate causes for the switching I-20 / 21 =

from 1 to 0. Possible causes are:
DISTURBANCE 63: DCM-DIE CLOSED 2

- 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.

DISTURBANCE 64: DCM-DIE READY FOR

INJECTION 1

- was not switched to 1 during die
shut movement
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
In MANUAL mode or AUTO-DOS RUN, 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:
DISTURB.-64: DCM-DIE READY F. INJECT. 1

during dosing mode
- 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

- signal has not been switched to 1
during closing movement
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURB.-66: PLUNGER IN BACK POSIT.

in dosing mode
- OPEN DIE and
- ADVANCE PLUNGER !
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
DISTURB.-67: DCM PLUNGER NOT MOVED
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
Version: 03.00 A
3-6
05.03

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.

DISTURBANCE 66: DCM PLUNGER IN BACK

POSITION
In MANUAL mode or AUTO-DOS RUN, the
I-24 = from 25.40 mm to 1.

to 0.
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)

to 0.
DISTURBANCES

OPERATING MANUAL

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
Version: 03.00 A
DOSING CONTROL

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
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

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
DISTURB.-70: DISCONT. SYNCHRO OPERATION

- after metal feed start (after DC)
signal switches from 0 to 1
- 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
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
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
INJECTION 1 = 0

= 0
DIST.
ACKNO.
MODIFY
DATA
kg-DOS:
DOSING
NEW
In AUTO-DOS RUN after lapse of program time

t5 -END = RELEASE FOR INJECTION,
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)

to 0..
DISTURBANCES

05.03
6-6
0503-B.doc
blank page
Version: 03.00 A

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
/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
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
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
- see chapter 06.05

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
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)
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.
HELP FUNCTIONS
GENERAL DESCRIPTION
06.00
4-4
0600-A.doc
blank page
Version: 12.99 A

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
2 - 02.03.00 - 06:12:16
3 - 01.03.00 - 09:37:41
4 - 01.03.00 - 08:24:21
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

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.
ESC .
HELP FUNCTIONS
I/O(INPUT / OUTPUT) LEVEL

2-6
06.02
0602-A.doc
Version: 12.99 A

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
DATA
ANALOG
DIGITAL SIGNALS
INIT
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
Press key
F 4 = DIGITAL IN / OUT:
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

06.02
4-6
0602-A.doc
Version: 12.99 A

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:
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
F4 = Displ. of DIGITAL
INPUTS and OUTPUTS
F5 = Display of SIGNALS between
DATA
ANALOG
DIGITAL SIGNALS
INIT
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
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:

- access is code-locked:
- follow instructions
Enter CODE-NO. and press key:

***BASIC STATUS***
10.03.00 CELL IND.
14:31:17
DOS. PIPE: 100/35mm
use

MANUAL
******
- OUTPUT: = output signal

- No.
= input / output number
- OUT:
= current switch status:
- 0 = OFF
- 1 = ON
to place cursor at output
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

06.02
6-6
0602-A.doc
blank page
Version: 12.99 A

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

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

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
press key
DATA DISPLAY

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

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
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
F4
to display the process data of the last five dosing

processes:
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

OPERATING MANUAL
DATA DISPLAY
4-8
06.04
0604-B.doc
Version: 03.00 B
DOSING CONTROL
DATA LOG
F5
The saved data (grouped into chapters K01 to K27) of

the individual dosing processes are displayed:
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
207883
+49(0)2261
7091140
7091129
0
2.5

1
= (CELL = 1 / HPDE = 0)
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
-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

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
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
10.845
s = t-DC-MIN-time
1.845
s = t-DC/TS-MIN-time
FILLING LEVEL SYSTEM with HPDE:
= HPDE NOT ACTIVE
10.03.00
= setup date
900
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

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

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

01:
02:
03:
04:
05:
06:
07:
08:
09:
10:
7-8
ESC .
HELP FUNCTIONS

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
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
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
= 10942:43/h
MEMORY
= JA
MEMORY
= NEIN
ZURCK
EINGABE
ESC .
HELP FUNCTIONS
i / T (INFO / TEMPERATURES)
06.05
2-2
0605-A.doc
blank page
Version: 12.99 A

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
HELP FUNCTIONS
0606-A.doc
Version: 12.99 A
1-2
ERROR
I-/O
HISTORY
LEVEL

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
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
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

OPERATING MANUAL

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
F1
(MEMORY=YES) = save
and back to initial status
F2 - DO NOT SAVE DATA MODIFICATION AND

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
- 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

OPERATING MANUAL
PRINTER
2-6
06.07
0607-B.doc
Version: 03.00 B
DOSING CONTROL
PROCEDURE
press key
PRINT
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
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
27.02.00
- 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

completion.
02.03.00
10:42
K25. TEMPERATURE-REDUCTION (MELT)

03.03.00 = setup date
FRIDAY
23:30
= time
MONDAY
= end of reduction
03:45
= time
- 70
= temperature reduction value
03.03.00
= setup date
= warm-up in 4h + 20h
690
= end 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
5
1
= XsdAL1 Hyst. undertemp.
melt
1
= XsdAL2 Hyst. overtemp. melt
0
= Temperature-Offset
875
5
= XsdAL3 Hyst.furnace chamb. temp.
750
= AL-08-HEATING overtemperature
640
= AL-08-HEATING undertemperature
20
= full to part. load
40
= at part. load OFF
30
= OFF to part. load
5
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.
completion.
HELP FUNCTIONS

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
Electrode or PneuCo
CELL or HPDE
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.
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.
HELP FUNCTIONS

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

+ 0.00 kg = AUTO-increase up to 1.75
-0.95 kg = AUTO-decrease up to 0.95
34
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
F1

F2 - DO NOT SAVE DATA MODIFICATION
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

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
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

OPERATING MANUAL
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
Dosing pipe size

Current date
Current time
Installed software version
Setup date
Melt available in furnace in kg

P r o D o s
is only an example and may deviate from the actual

values.
03.03.00
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

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

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

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
multi-function key F 2 = SETUP in BASIC

STATUS.
P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE:
SETUP MODE
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

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
07.00
The visualisation field shows the currently saved

F1: LOG DATA .....................
F4: kg-DIAGRAM ...................
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.
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,

The SETUP MODE is now accessible. The
display changes to the ENTRY FORM.

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
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.
MANUAL
After pressing key

the SETUP MODE is accessible. The display
changes to the ENTRY FORM.
SETUP MODE

OPERATING MANUAL
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

save):
proceed with the next entry.
To save data - press key
F1
MEMORY = YES:
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
??
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
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
In BASIC STATUS of the Pro Dos DPC, press
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
SETUP MODE:
F3
F4
F5
F1
F4

general SETUP MODE:
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F3
F 2 = SETUP
10.03.00
13:34
F = MENU / ESC=back
F2
multi-function key
values of the individual setup option:


F1: LOG DATA .....................
F4: kg-DIAGRAM ...................
LOG
DATA
F5
Select - LDT-SETUP by pressing
multi-function key
F3 .
SETUP MODE

2-6
07.01
0701-B.doc
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
ATTENTION:

ALWAYS
COMPLY
WITH
SAFETY
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).
press multi-function key F 3


to access SETUP OPTIONS for:
LANGUAGE - select
DATE - enter
TIME - enter
10.03.00
SETUP MODE:
13:34:57
LANGUAGE/DATE/TIME
MANUAL
******
press multi-function key F 3

The display form with instructions appears.
10.03.00
SETUP MODE:
13:34:57
LANGUAGE/DATE/TIME
Press key
to access SETUP OPTIONS for:
Select LANGUAGE
Set DATE
Set TIME

MANUAL
WESTOMAT ProDos DPC

OPERATING MANUAL
SETUP MODE

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
The LANGUAGE setup is now completed.
SETUP MODE

OPERATING MANUAL

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
F3 = set time
F4 = set date
multi-function key
displayed:
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
press key
STATUS
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

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
F3 = set time
F4 = set date
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
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
SETUP MODE

07.01
6-6
0701-B.doc
blank page
Version: 03.00 B

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

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
In BASIC STATUS of the Pro Dos DPC, press:
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL.
DOS. PIPE 80/24mm 13:34:57
!

P r o D o s
03.03.00
multi-function key
The display changes to the general SETUP MODE:
F 2 = SETUP

values of the individual setup options:
From this status - SETUP LOG DATA by

pressing
multi-function key
F1 .
The display changes to the form with operating

instructions.
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
SETUP MODE:
F3
F4
F5
10.03.00
13:34
F = MENU / ESC=back

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

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:
ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
10.03.00
SETUP MODE:
13:34:57
LOG DATA



MANUAL
******
F1

The
SETUP
MODE
for
DATA
and
PARAMETERS is now accessible. The display
10.03.00
SETUP MODE:
13:34:57
LOG DATA

F1
Press key
The
SETUP
MODE
for
DATA
and
PARAMETERS is now accessible. The display

MANUAL
The display with instructions appears
ENTER data as follows:
Press
Entry: e.g.
or
...
, press key
and

save):
F1
MEMO and:
MEMORY = YES:
The new values are saved.
SETUP MODE

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
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
207883
+49(0)2261
7091140
7091129
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
- 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
- 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
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.
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

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
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.
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.
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.
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

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
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
- 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
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
9 - 14
07.02
PROPORTIONAL PART P2 for regulation of

furnace chamber pressure after DC:
ATTENTION:
K07. PRES. REG. CIRC. FURN. CHAMB.: cont.

20.00
= P2-cont. regul. (after DC)
10.00
s = integral action time
and continue with
READJUSTMENT TIME (I-part) for regulation of

the furnace chamber pressure:
ATTENTION:
15.0
K 08 - Data on rates of pressure rise in furnace

chamber:

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
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

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
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:
65
mm = inner diameter
21
mm = nozzle bore
199
- 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.
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 (!).
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

0
mm = inner diameter
0
mm = nozzle bore
0
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.
- 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

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
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
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
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
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

save):
ATTENTION:
If only one parameter (i.e. one file) has been

modified, the changes can be saved immediately
after entry.

F5 - BACK TO ENTRY
MEMORY
= YES
MEMORY
= NO
BACK TO
ENTRY
F1
F1
F2
F3
F4
F5
MEMORY = YES:
F3
MEMO and:
MEMORY = NO:

F5
BACK TO ENTRY:

displayed;
additional
entries
and
The setup of the LOG DATA is now completed.
Press key
press key
STATUS
SETUP MODE

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:
07.03.1
WEEKEND TEMPERATURE REDUCTION See

chapter 07.03.2
FIRST WARM-UP see chapter 07.03.3
see
chapter
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

OPERATING MANUAL

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

temperature of melt:
standard program
Warm-up in 52h + 20h

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
***BASIC STATUS ***

10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
multi-function key
F 2 = SETUP
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE:
SET-UP MODE

0703-B.doc
Version: 03.00 B
10.03.00
13:34
F = MENU / ESC=back

general SETUP MODE:
=
=
=
=
=

1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
SETUP
LEVEL
GRAM
HEATING
Select - REGULATOR HEATING by pressing

multi-function key
F1
F2
F3
F4
07.03

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
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

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
MANUAL
******
F1

the code number appears.

The SETUP MODE for the respective settings is
now accessible.
SETUP MODE

0703-B.doc
4-4
07.03
Version: 03.00 B
Press key
the
respective
To enter settings, proceed as follows and complete

procedure by saving entries:
Press
Entry: e.g.
or

...
, press key
and

save):
F1

MANUAL
The SETUP MODE for

settings is now accessible.
DOSING CONTROL
10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
F?

OPERATING MANUAL
MEMO and:
MEMORY = YES:
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
REGULATOR HEATING
07031-B.doc
Version: 03.00 B
1-8
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key F 2 = SETUP

general SETUP MODE:

SETUP MODE:

F1: LOG DATA ......................
F2: FILL LEVEL INDICATION .........
F4: kg-DIAGRAM ....................
LOG
DATA
F1

10.03.00
13:34
F = MENU / ESC=back
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

multi-function key
F5 .
SETUP MODE
REGULATOR HEATING

OPERATING MANUAL
07031-B.doc
2-8
07.03.1
Version: 03.00 B

Select pressing
REGULATOR
CONFIGURATION
by
DOSING CONTROL
10.03.00
SETUP MODE:
13:34:57
REGULATOR-HEATING
INFO
FIRST
T-REDWARM-UP UCTION
F5 .
multi-function key
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
F1
F2
F3
F4
CONFIGUR
.
REGULAT
F5

in the log (K 12).
F5

10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.

now accessible.

MANUAL
******
F5
Press key
The SETUP MODE for

the
respective
Press
or
Entry: e.g.

...
, press key
and

save):
F1

MANUAL
ENTER data as follows:
10.03.00
SETUP MODE:
13:34:57
REGULATOR CONFIGUR.
MEMO and:
MEMORY = YES:
The new values are saved.
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
REGULATOR HEATING
07031-B.doc
Version: 03.00 B
3-8
07.03.1
DATA INPUT:
10.03.00
SETUP MODE:
13:34:42
REGULATOR CONFIGUR.
- The existing data (for K 27 and last setup date)

are displayed:
ATTENTION

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
Rate time
s = Tn
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:
Delay FULL/PARTIAL
and continue with
C Y1 - MINIMUM DURATION HEATING OFF:
5
s = Cy1 MIN duration heating OFF
and continue with
C Y2 - MINIMUM DURATION HEATING ON:
5
5
s = Cy2 MIN duration heating ON
and continue with
T SH-MIN - TOGGLING
PARTIAL LOAD:
4

INFO
and continue with
TIME
from
FULL
to
SETUP MODE
REGULATOR HEATING
4-8
07.03.1
07031-B.doc
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
10.03.00
SETUP MODE:
13:34:56
REGULATOR CONFIGUR.
,
INPUT,
ENTER
and
MEMO / ESC=back

T SH-MAX - TOGGLING TIME from PARTIAL
FULL LOAD:
to
= XsdAL1 Hyst. undertemp.
= XsdAL2 Hyst. overtemp. melt
5
and continue with
X SD-AL1 - HYSTERESIS for the monitoring of the

MELT UNDERTEMPERATURE and the activation of
the DISTURBANCE (dosing locked):
melt
1
and continue with
X SD-AL1 - HYSTERESIS for the monitoring of the

MELT OVERTEMPERATURE and the activation of
the DISTURBANCE (dosing locked):
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
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
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
07031-B.doc
10.03.00
SETUP MODE:
13:34
REGULATOR CONFIGUR.
Version: 03.00 B
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

750
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

6
640
and continue with
= AL-08-HEATING-undertemperature
EMERGENCY HEATING
ATTENTION
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

OPERATING MANUAL
6-8
07.03.1
07031-B.doc
At PARTIAL LOAD while HEATING is OFF switching threshold of heating at increasing

furnace chamber temperature:
Version: 03.00 B
DOSING CONTROL
10.03.00
SETUP MODE:
13:34
REGULATOR CONFIGUR.
,
INPUT,
ENTER
and
MEMO / ESC=back

50
= at part. load OFF
35
= OFF to part. load
and continue with
From HEATING OFF to PARTIAL LOAD switching threshold of heating at decreasing

furnace chamber temperature:

and continue with
From PARTIAL to FULL LOAD - switching

threshold of heating at increasing furnace
chamber temperature:

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
after entry.
F1
MEMO and:
MEMORY = YES:
10.03.00
SETUP MODE:
13:34:54
REGULATOR CONFIGUR.
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
07031-B.doc
Version: 03.00 B
MEMORY = NO:

F5
BACK TO ENTRY:

displayed;
additional
entries
and
The
setup
procedure
for
the
CONFIGURATION is now completed.
REGULATOR
Press key
press key
STATUS
7-8
07.03.1
SETUP MODE
REGULATOR HEATING
07.03.1
8-8
07031-B.doc
blank page
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
REGULATION HEATING
07032-B.doc
Version: 03.00 B
1-4
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
SETUP MODE:
F3
F4
F5
F1
multi-function key

general SETUP MODE:
10.03.00
13:34
F = MENU / ESC=back
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F 2 = SETUP


F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
F5

multi-function key
F5 .
SETUP MODE
REGULATION HEATING

OPERATING MANUAL
07032-B.doc
2-4
07.03.2
Version: 03.00 B

Select - T-REDUCTION by pressing
DOSING CONTROL
10.03.00
SETUP MODE:
13:34:57
REGULATOR-HEATING
multi-function key
F4 .
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
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.
The display form with instructions for entry of the

code number appears.
10.03.00
SETUP MODE:
13:34:57
TEMPERATURE
REDUCTION

F4

now accessible.

MANUAL
******
F4
Press key
10.03.00
SETUP MODE:
13:34:57
TEMPERATURE RED.
The SETUP MODE for

the
respective

MANUAL
Enter data as follows:

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
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
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

OPERATING MANUAL
4-4
07.03.2
07032-B.doc
Version: 03.00 B
DOSING CONTROL
SAVING TEMPERATURE REDUCTION

save):
ATTENTION:
after entry.
MEMO and:
10.03.00
SETUP MODE:
13:34:54
TEMPERATURE RED.
F1
F3
MEMORY = YES:
F5 - BACK TO ENTRY
MEMORY = NO:

F5
MEMORY
= YES
F1
BACK TO ENTRY:

displayed;
additional
entries
and
The setup procedure for the

REDUCTION is now completed.

TEMPERATURE
Press key ESC - display returns to initial status
press key
STATUS.
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
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
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

OPERATING MANUAL
FIRST WARM-UP
07.03.3
2-6
07033-B.doc
Version: 03.00 B
DOSING CONTROL
SETUP PROCEDURE
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 100/35mm
!

P r o D o s
03.03.00
INFO
multi-function key

general SETUP MODE:
F 2 = SETUP

F1
F5 .
F2
SETUP MODE:
F3
F4
F5
10.03.00
HEATING
13:34
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................

multi-function key

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
LOG
DATA
F1
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

Select - FIRST-WARM-UP by pressing

10.03.00
HEATING
SETUP MODE:
13:34
SCAN=CELL
REGULATOR-HEATING
F = MENU / ESC=back
multi-function key
F3 .
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

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
10.03.00
HEATING
SETUP MODE:
13:34:57
SCAN=CELL
FIRST WARM-UP
F3


MANUAL
******

The SETUP MODE for the activation (or
deactivation) of the FIRST WARM-UP is now
available.

10.03.00
HEATING
SETUP MODE:
13:34:57
SCAN=CELL
FIRST WARM-UP
MANUAL
F3
The SETUP MODE for the activation (or

deactivation) of the FIRST WARM-UP is now
available.

... 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
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

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).
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
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.

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).
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

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)

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.
in CELL-SIGNAL COMPENSATION:
subsequent compensation of CELL signal re.
operating modes of furnace
CELL-DATA ENTRY:
technical data of CELL and
furnace filling level data
SETUP MODE

OPERATING MANUAL

2-6
07.04
0704-B.doc
Version: 03.00 B
DOSING CONTROL
for the
hydraulic-pneumatic pressure detection

system (HPDE):
in HPDE -DATA ENTRY:
furnace filling level data

cycle time for LEVEL-SCANNING

realization of dosing contact if FURNACE
FULL.
These parameters apply to both CELL and
HPDE system.
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
multi-function key
F 2 = SETUP
F1

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
=
=
=
=
=

1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
07.04
10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
3-6
Select pressing
FILLING
multi-function key
F5
LEVEL
INDICATION
by
F2 .
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in LOG K 12.
10.03.00
SETUP MODE:
13:34:57
SCAN=CELL
CELL-FILLINGINDICATION
F2


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

MANUAL
******
F2
10.03.00
SETUP MODE:
13:34:57
SCAN=CELL
MANUAL
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

OPERATING MANUAL

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
F 4 = DISPLAY MODE
F 5 = SWITCHING THRESHOLDS
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 .

CELL SETUP:
F 2 = CELL-DATA ENTRY
- see chapter 07.04.3.1
F 3 = CELL-mA-SIGNAL
F 4 = chapter P/t-MIN-MEASURING
10.03.00
SETUP MODE:
13:34:51
SCAN=CELL
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.
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
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.
F1
F2
F3
F4
F5

general SETUP MODE:
F 2 = HPDE-SYSTEM
F 4 = DISPLAY MODE
F 5 = SWITCHING THRESHOLDS
In HPDE-SYSTEM, press
multi-function key
F2 .

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:
INFO
DATA
P/t-MIN
ENTRY
MEASURE
F1
F2
F3
F4
F5
F 4 = HPDE-DATA ENTRY
F 5 = chapter P/t-MIN-MEASURING
SETUP MODE

07.04
6-6
0704-B.doc
blank page
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
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
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.
***BASIC STATUS ***

10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key
F 2 = SETUP
SETUP MODE

OPERATING MANUAL
DISPLAY MODE
07.04.1
2-4
07041-B.doc
Version: 03.00 B
SETUP MODE:

Select
pressing
FILLING-LEVEL-INDICATION
DOSING CONTROL
10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
by
LOG
DATA
multi-function key F 2 .
ATTENTION
F1

ALWAYS
COMPLY
WITH
SAFETY
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

in the log (K 12).
F2


for the SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
13:34:57
CELL-FILLINGSCAN=CELL
INDICATION
MANUAL
******
F2
Press
for the SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
13:34:57
CELL-FILLINGSCAN=CELL
INDICATION
MANUAL
SETUP MODE
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
detection system
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
Mode -1: FURNACE FULL = lamps ON

Mode -2: FURNACE FULL = lamps OFF
Mode -3: BATH LEVEL = one lamp ON
... 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

save):
10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
DISPLAY MODE

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
press key
STATUS.
SETUP MODE

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
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
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.
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key
F 2 = SETUP
SETUP MODE

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
Version: 03.00 B
SETUP MODE:

LOG
DATA
F2 .
10.03.00
HEATING
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................

multi-function key
DOSING CONTROL
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
F1
F2
F3
F4
F5

in LOG K 12.
F2


The SETUP MODE for the CELL FILLING
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
HEATING
10.03.00
SETUP MODE:
SCAN=CELL
13:34:57
CELL-FILLING-INDICA
MANUAL
******
F2
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
HEATING
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
SETUP MODE
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
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
F = MENU / ESC=back
detection system
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:
F = MENU / ESC=back
(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:
, 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:
save):
F1
F5 - BACK TO ENTRY
MEMORY
= YES
F1
MEMORY
= NO
F2
F3
BACK TO
ENTRY
F4
F5
MEMO and:
MEMORY = YES:
F3
MEMORY = NO:

previous values remain saved.
F5

to place cursor in desired line
10.03.00
SETUP MODE:
F5 .
BACK TO ENTRY:
The display returns to initial status and

be made.
SETUP MODE

OPERATING MANUAL
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:
F = MENU / ESC=back
(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
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:
save):
F1
MEMO and:
MEMORY = YES:
10.03.00
SETUP MODE:

F3
MEMORY = NO:

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;
be made.
The setup of the SWITCHING THRESHOLDS is now

completed.
Press key
press key
STATUS

F5 - BACK TO ENTRY
MEMORY
= YES
F1
MEMORY
= NO
F2
F3
BACK TO
ENTRY
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
SETUP MODE
07043-B.doc
DOSING CONTROL
Version: 03.00 A
1-4
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
SETUP MODE:
F3
F4
F5
F1
multi-function key
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5
F 2 = SETUP

10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
Select - FILL LEVEL INDICATION by pressing

multi-function key
F2 .
SETUP MODE

07.04.3
2-4
07043-B.doc
Version: 03.00 A

OPERATING MANUAL
DOSING CONTROL
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
F2


SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
******
F2
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
Select - CELL SYSTEM by pressing
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back

INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.
F1
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE

07043-B.doc
Version: 03.00 A
The setup procedures for CELL filling level scanning

must be entered and saved as follows:
CELL -DATA ENTRY:
CELL-mA-SIGNAL:

technical data of CELL and
furnace filling level data:
kg-values, valid for both CELL and HPDE
system (see chapter 07.04.4.1)

compensation of CELL signal
operating modes of furnace
re.
actual

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:

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
F = MENU / ESC=back
INFO
DATA
CELLP/t-MIN CORRECT.
ENTRY
mAMEASUR. SIGNAL
SIGNAL:
F1
F2
F3
F4
F5
SETUP MODE

07.04.3
4-4
07043-B.doc
blank page
Version: 03.00 A

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
Signal value of CELL at QN-LOAD:

- mA-signal of CELL with nominal load
The setup date of the CELL DATA ENTRY is entered

automatically in LOG K 15.
SETUP PROCEDURE
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 65/21mm 13:34:57
!

P r o D o s
03.03.00
INFO

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F1
F2
F3
F4
F5
multi-function key
F 2 = SETUP
SETUP MODE
FILLING LEVEL INDICATION / CELL

OPERATING MANUAL
DATA ENTRY
07.04.3.1
070431-B.doc
2-6
Version: 03.00 A
SETUP MODE:
10.03.00
13:34:57


multi-function key
F2 .
SCAN=CELL
F = MENU / ESC=back
F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
F1
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
DOSING CONTROL
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

in LOG K 12.
F2


SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
******
F2
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
DATA ENTRY
070431-B.doc
Version: 03.00 A
3-6
07.04.3.1
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back

INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.
multi-function key
F1
F2
F3
F4
F2 .
F5
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back
Select - DATA ENTRY by pressing

INFO
DATA
ENTRY
mAMEASUR. SIGNAL
SIGNAL
F1
F2
F3
F4
F2 .
F5
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-DATA ENTRY
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
and continue with
SETUP MODE

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
- 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.
and continue with

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.
and continue with
ATTENTION
Values for:
REFILL CHARGE:
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
DATA ENTRY
070431-B.doc
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-DATA ENTRY
Version: 03.00 A
07.04.3.1
CELL NOMINAL LOAD (QN):

- according to type plate of load cell

2000
5-6
daN = CELL-nominal load (Qn)
and continue with
MIN-signal-CELL in mA:
- Output signal of CELL without load
- 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
- 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:
and DATA
SETUP MODE

OPERATING MANUAL
DATA ENTRY
6-6
07.04.3.1
070431-B.doc
Version: 03.00 A
DOSING CONTROL

save):
F1
MEMO and:
MEMORY = YES:
10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
CELL-DATA ENTRY
F5 - BACK TO ENTRY
F3
MEMORY = NO:

MEMORY
= YES
F1
F5
BACK TO ENTRY:

displayed;
additional
entries
and
The setup procedure for the CELL-DATA ENTRY is

now completed.
Press key
press key
STATUS
MEMORY
= NO
F2
F3
BACK TO
ENTRY
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
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:
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key
F2
= SETUP
SETUP MODE

OPERATING MANUAL
CELL-mA-SIGNAL
07.04.3.2
2-6
070432-B.doc
Version: 03.00 B
SETUP MODE:

LOG
DATA
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................

DOSING CONTROL
F1
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

in the log (K 12).
F2


SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
******
F2
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
CELL-mA-SIGNAL
070432-B.doc
Version: 03.00 B
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back
3-6
07.04.3.2

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
F = MENU / ESC=back
F2 .
Select - CELL-mA-SIGNAL by pressing

INFO
DATA
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

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
K16. CELL-mA-SIGNAL
4.014
6.014
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
K16. CELL-mA-SIGNAL
4.083
6.014
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
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
VALUE = 13.187
Transfer this signal value for FURNACE

WITHOUT MELT by pressing
key
OPERATING LEVEL EMPTY.
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
K16. CELL-mA-SIGNAL
4.083
6.014
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
K16. CELL-mA-SIGNAL
4.083
13.187
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
CELL-mA-SIGNAL
070432-B.doc
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
CELL-mA-SIGNAL
K16. CELL-mA-SIGNAL
4.083
13.187
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
Version: 03.00 B

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).
additional weight and the cleaning door is
closed

=
=
=
=
IMPORTANT NOTES
- The setup for the mA-value for the CELL
ZERO POINT and FURNACE WITHOUT
MELT is now completed.
zero-point
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
4.083
13.187
14.075
11.014
INFO
5-6
zero-point

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
K16. CELL-mA-SIGNAL
4.083
13.187
14.075
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point

OPERATING LEVEL FULL.
OPERATING LEVEL FULL:

maximum operating level of melt = FULL
- recommended value = see table

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

additional weight and the cleaning door is
closed
K16. CELL-mA-SIGNAL

VALUE = 16.396

4.083
13.187
14.075
16.396
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
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

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

save):
To save data - press key MEMO and:
F1
F3
MEMORY = YES:
MEMORY = NO:

F5
10.03.00
SETUP MODE:
13:34:54
SCAN=CELL
CELL-mA-SIGNAL
F5 - BACK TO ENTRY
MEMORY
= YES
MEMORY
= NO
BACK TO
ENTRY
BACK TO ENTRY:

displayed;
additional
entries
and
The setup of the CELL -mA-SIGNAL is now completed.
Press key
press key
STATUS
F1
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
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

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
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 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
***BASIC STATUS***
10.03.00
HEATING
SCAN=CELL
DOS. PIPE 65/21mm 13:34:57
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
SETUP MODE

OPERATING MANUAL
P/t-MIN-MEASURING
07.04.3.3
4 - 10
070433-B.doc
Version: 03.00 B
SETUP MODE:
10.03.00
13:34:57

SCAN=CELL
F = MENU / ESC=back
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

LOG
DATA
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
DOSING CONTROL
F1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

in the log (K 12).
F2


SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
SETUP MODE:
CELL-FILLING-INDICA
10.03.00
13:34:57
SCAN=CELL

MANUAL
******
F2
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
SETUP MODE
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
F = MENU / ESC=back
5 - 10
07.04.3.3
The display changes to selection mode.
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.

multi-function key
F1
F2
F3
F4
F2 .
F5
SETUP MODE:
CELL-FILLING-INDICA
10.03.00
13:34:51
SCAN=CELL
F = MENU / ESC=back
DATA ENTRY
CELL-mA-SIGNAL
P/t-MIN-MEASURING
SIGNAL COMPENSATION

INFO
DATA
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
or
pipe line
10.03.00
HEATING
SETUP MODE:
SCAN=CELL
DOSING PIPE SELECTION
to place cursor in dosing
and press key

The display changes to the setup mode for
P/t-MIN-MEASURING
SETUP MODE

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
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
Position error: I-24 = 1 / ESC=back
I-24 PLUNGER IN BACK POSITION (DCM)
= 1

DOSING
DCM plunger is moved out
10.03.00
HEATING
SETUP MODE:
SCAN=CELL
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 !

The DCM die closes in position MANUAL.

completely !

To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
MANUAL POSITION!
DOSING
SETUP MODE
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
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
MANUAL POSITION!
The DCM die is further closed in position

MANUAL
The DCM die is fully closed in position

MANUAL = ready for injection.

To DOSING by HAND:
- Press external key DOS-Onto activate

WESTOMAT status ready for injection
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
... 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

t6
DC
t3
t4
t5
28.74
DOSING
by HAND
SETUP MODE

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
... RUN
t6
lag time after furnace pressure release followed by
t7
DCM-DIE
TS=
DC
t2
p =
t3
t4
t5
8.29

t6
t7
DCM-DIE
second pressure rise to DC -2 (P-DC-2) started
TS=
DC
t2
p =
t3
t4
t5
12.37

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

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
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

t6
t7
DCM-DIE
TS=
DC
t2
p =
t3
t4
t5
18.75
DOSIERENv
on HAND
SETUP MODE
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
... RUN
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:
ENTER = continue
HEATING
SCAN=CELL
K21.REFERENCE-kg-DIAGR.65/21mm=NO 1:
OPERATING INSTRUCTION:
- OPEN DIE and
- ADVANCE PLUNGER !
DOSING
10.03.00
SETUP MODE:
SCAN=CELL
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
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

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

save):
F1
MEMORY = YES:

MEMORY = NO:

F5
The setup
completed.
F5 - BACK TO ENTRY
MEMORY
= YES
MEMORY
= NO
BACK TO
ENTRY
BACK TO ENTRY:

displayed;
additional
entries
and
of
10.03.00
13:34:54
SCAN=CELL
F3
SETUP MODE:
CELL: P/t-MIN-MEAS.
MEMO and:
the
P/t-MIN-MEASURING
is
now
Press key
press key
STATUS
F1
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
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:
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:
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

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:

***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!
multi-function key
F 2 = SETUP
P r o D o s
03.03.00
INFO
F1

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
Version: 03.00 B
10.03.00
13:34:57
SCAN=CELL
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
F1
=
=
=
=
=
F3
F4

1
1
1
1
1
F5
07.04.3.4

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
3-6

multi-function key
F2 .
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
10.03.00
SETUP MODE:
SCAN=CELL
F2



SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

MANUAL
******
F2

10.03.00
SETUP MODE:
SCAN=CELL
MANUAL
Press
SETUP:
C E L L SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
SETUP MODE

OPERATING MANUAL
SIGNAL COMPENSATION
07.04.3.4
4-6
070434-B.doc
Version: 03.00 B
DOSING CONTROL
10.03.00
13:34:51
SCAN=CELL
F = MENU / ESC=back
INFO
CELL
DISPLAY SWITCH.
SYSTEM
MODE
THRESH.
multi-function key
F2 .
F1
F2
F3
F4
F5
Select SIGNAL COMPENSATION by pressing
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back
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

INFO
DATA
ENTRY
mAMEASUR. SIGNAL
SIGNAL
F1
F2
F3
F4
F5
10.03.00
SETUP MODE:
13:34:58
SCAN=CELL
SIGNAL COMPENSATION
K16. CELL-mA-SIGNAL
4.054
6.014
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
SIGNAL COMPENSATION
070434-B.doc
10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
K16. CELL-mA-SIGNAL
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
The measuring of the mA-signal is

VALUE = 4.083
- The cursor is placed in the ZERO POINT

line
10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
- 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
6.014
8.014
11.014
INFO
mA
mA
mA
mA
=
=
=
=
zero-point
The cursor is automatically set to line

operating level
10.03.00
SETUP MODE:
13:34:58 SCAN=CELL
SIGNAL COMPENSATION
K16. CELL-mA-SIGNAL
FURNACE FULL:
maximum operating level of melt = FULL

4.083
13.187
14.075
11.014
INFO
mA
mA
mA
mA
=
=
=
=
IMPORTANT NOTES
OPERATING LEVEL FULL
zero-point

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
4.083
13.187
14.075
16.396
INFO
Transfer this signal value for ZERO POINT

by pressing
mA
mA
mA
mA
=
=
=
=
zero-point
The measuring of the mA-signal is

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

OPERATING MANUAL
SIGNAL COMPENSATION
6-6
07.04.3.4
070434-B.doc
Version: 03.00 B
DOSING CONTROL
... SAVING CELL-mA-SIGNAL

save):
MEMO and:
10.03.00
SETUP MODE:
13:34:54 SCAN=CELL
SIGNAL COMPENSATION
F1
MEMORY = YES:

F5 - BACK TO ENTRY
F3
MEMORY = NO:

F5
BACK TO ENTRY:

displayed;
additional
entries
and
The setup of the CELL-mA-SIGNAL COMPENSATION

is now completed.
Press key
press key
STATUS
MEMORY
= YES
F1
MEMORY
= NO
F2
F3
BACK TO
ENTRY
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
07044-B.doc
Version: 03.00 B
1-4
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key
F 2 = SETUP
SETUP MODE:
10.03.00
13:34:57
SCAN=HPDE
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
F1

=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

multi-function key
F2 .
SETUP MODE

07.04.4
07044-B.doc
2-4
Version: 03.00 B

OPERATING MANUAL
DOSING CONTROL
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
F2


The SETUP MODE for the HPDE FILLING
SETUP:
H P D E SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=HPDE
HPDE-FILLING INDICA 13:34:57
MANUAL
******
F2
10.03.00
SETUP MODE:
SCAN=HPDE
Press
SETUP:
H P D E SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

MANUAL
Select - HPDE SYSTEM by pressing
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back
detection system
multi-function key
F2 .

INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.
F1
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE

07044-B.doc
10.03.00
SETUP MODE:
F = MENU / ESC=back
Version: 03.00 B
The setup procedures for HPDE filling level scanning

must be entered and saved as follows:
F5 = P/t-MIN MEAS: when furn. full:

DATA
ENTRY
P/t-MIN
MEASUR.
in HPDE -DATA ENTRY:
cycle time for LEVEL-SCANNING
furnace filling level data:
F1
F2
F3
F4
07.04.4
SCAN=HPDE
INFO
3-4
F5
kg-values, valid for both HPDE and CELL

system (see chapter 07.04.4.1)

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

07.04.4
4-4
07044-B.doc
blank page
Version: 03.00 B

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.

- 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.

- 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
!


P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
multi-function key
F 2 = SETUP
SETUP MODE

OPERATING MANUAL
DATA ENTRY
07.04.4.1
070441-B.DOC
2-6
Version: 03.00 B
SETUP MODE:

Select pressing
FILLING
multi-function key
LEVEL
INDICATION
DOSING CONTROL
10.03.00
13:34:57
SCAN=HPDE
F = MENU / ESC=back

F1: LOG DATA = 1
F3: LDT - LANGUAGE/DATE/TIME ......
F4: kg-DIAGRAM ....................
by
LOG
DATA
F2 .
F1
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
=
=
=
=
1
1
1
1
AVAILABLE = 1,040 kg MELT

FILL
LDT
kg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

in LOG K 12.
F2


SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=HPDE
MANUAL
******
F2
Press
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=HPDE
MANUAL
WESTOMAT ProDos DPC

BEDIENANLEITUNG
DOSING CONTROL
SETUP MODE
DATA ENTRY
070441-B.DOC
Version: 03.00 B
3-6
07.04.4.1
10.03.00
SETUP MODE:
SCAN=HPDE
F = MENU / ESC=back
detection system
INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.
multi-function key
F1
F2
F3
F4
F2 .
F5
10.03.00
SETUP MODE:
SCAN=HPDE
F = MENU / ESC=back

INFO
DATA
ENTRY
P/t-MIN
MEASUR.
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
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
7
700
INFO
and continue with
SETUP MODE

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

- 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.
and continue with
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.
and continue with
ATTENTION
Values for:
REFILL CHARGE:
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
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

- STANDARD value = 10 sec

- Min. value = 5 sec
- Max. value = 15 sec
10
s = Cycle for LEVEL-SCANNING
INFO
and continue with
The entry procedure for

ENTRY is now completed:
the
HPDE-DATA

save):

10.03.00
13:34:54
SETUP MODE:
HPDE-DATA ENTRY
SCAN=HPD
E
F1
MEMO and:
MEMORY = YES:
F3

MEMORY = NO:

F5 - BACK TO ENTRY
MEMO
= YES
F1
MEMO =
NO
F2
F3
BACK TO
ENTRY
F4
F5
F5
BACK TO ENTRY:

displayed;
additional
entries
and
The setup procedure for the HPDE-DATA ENTRY is

now completed.
Press key
press key
STATUS
SETUP MODE

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
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

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

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
P/t-MIN-MEASURING
070442-B.doc
Version: 03.00 B
3 - 10
07.04.4.2
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 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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
SETUP MODE

OPERATING MANUAL
P/t-MIN-MEASURING
07.04.4.2
070442-B.doc
4 - 10
Version: 03.00 B
SETUP MODE:
10.03.00
13:34:57

Select pressing
FILLING
multi-function key
LEVEL
INDICATION
DOSING CONTROL
SCAN=HPDE
F = MENU / ESC=back
F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
by
LOG
DATA
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2 .
F1
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
F2
F3
F4
F5

in LOG K 12.
F2


SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=HPDE
MANUAL
******
F2
Press
SETUP:
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD
10.03.00
SETUP MODE:
SCAN=HPDE
MANUAL
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE
P/t-MIN-MEASURING
070442-B.doc
Version: 03.00 B
10.03.00
SETUP MODE:
SCAN=CELL
F = MENU / ESC=back
5 - 10
07.04.4.2
detection system
HPDE-SYSTEM
DISPLAY MODE
SWITCHING THRESHOLD

INFO
HPDEDISPLAY SWITCH.
SYSTEM
MODE
THRESH.
F1
F2
F3
F4

multi-function key
F5
F2 .

SETUP MODE:
HPDE-FILLING INDICA
10.03.00
13:34:51
SCAN=HPDE
DATA ENTRY
P/t-MIN-MEAS.
F = MENU / ESC=back
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
or
line
10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
place cursor in dosing pipe
and press key

The display changes to the setup mode for
P/t-MIN-MEASURING
SETUP MODE

OPERATING MANUAL
P/t-MIN-MEASURING
07.04.4.2
6 - 10
070442-B.doc
Version: 03.00 B

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
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
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:
F2
F3
F4
F5
10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
I-24 PLUNGER IN BACK POSITION (DCM) .... =
1
DOSING

10.03.00
HEATING
SETUP MODE:
SCAN=HPDE
I-24 PLUNGER IN BACK POSITION (DCM) .... =
0


BACK POSITION !

the DCM die is closed in position MANUAL.

completely !

To DOSING by HAND:
I-19 DIE CLOSES (DCM) ........... = 1
MANUAL POSITION!
DOSING
SETUP MODE
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
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
MANUAL POSITION!

MANUAL


To DOSING by HAND:
- Press external key DOS-Onto activate

WESTOMAT status ready for injection
DOSING
MANUAL
SETUP MODE:
DOSING
HPDE: P/t-MIN-MEAS. SCAN=CELL
... ON
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
... RUN
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

t6
DC
t3
t4
t5
28.74
DOSING
by HAND
SETUP MODE

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
... RUN
t6
lag time after furnace pressure release followed by
t7
DCM-DIE
TS=
DC
t2
p =
t3
t4
t5
8.29

t6
t7
DCM-DIE
second pressure rise to DC -2 (P-DC-2) started
TS=
DC
t2
p =
t3
t4
t5
12.37
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
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
TS=
t4
7.59
t3
t4
t5
11.87

t6
t7
DCM-DIE
TS=
DC
t2
p =
t3
t4
t5
18.75
DOSING
by HAND
SETUP MODE
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
... RUN
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 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:
ENTER = continue
HEATING
SCAN=HPDE
K21. REFERENCE-kg-DIAGR.65/21mm=NO 1:
- OPEN DIE and
- ADVANCE PLUNGER !
DOSING
10.03.00
SETUP MODE:
SCAN=HPDE
10.03.00
= setup date
16.396 mA = HPDE at P/t-MIN-MEASURE
1.87 s = t-DC-MIN-time
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

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

save):
F1
MEMO and:
MEMORY = YES:
F3
10.03.00
SETUP MODE:
SCAN=HPDE

MEMORY = NO:
F5 - BACK TO ENTRY

F5
The setup
completed.
F1
BACK TO ENTRY:

displayed;
additional
entries
and
of
the
P/t-MIN-MEASURING
MEMORY
= YES
is
now
Press key
press key
STATUS
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

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:

15.0
7.5
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

65
21
146
mm = inner diameter
mm = nozzle bore

80
24
141
mm = inner diameter
mm = nozzle bore
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

03.03.00
= setup date
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

ALWAYS
COMPLY
WITH
THE
INSTRUCTIONS IN THIS MANUAL.
SAFETY
SETUP MODE

OPERATING MANUAL
kg-DIAGRAM
07.05
2-2
0705-B.doc
Version: 03.00 B
DOSING CONTROL
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
RDVs 06 and higher can only be realized if the

RDV-05 has been completed.
SETUP MODE
Kg-DIAGRAM

OPERATING MANUAL
07.05.1
2-8
07051-B.doc
Version: 03.00 B
DOSING CONTROL
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

scanning, supply channel) must be in perfect
working order.
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
multi-function key
F 2 = SETUP
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
F3
F4
F5
WESTOMAT ProDos DPC

OPERATING MANUAL
DOSING CONTROL
SETUP MODE:
SETUP MODE
Kg-DIAGRAM
07051-B.doc
Version: 03.00 B
10.03.00
13:34:57
F = MENU / ESC=back
F1
F3
F4
=
=
=
=
=

1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
07.05.1

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
3-8

multi-function key
F5
F4 .
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
F4


The SETUP MODE for REFERENCE DATA of
the kg-DIAGRAM is now accessible:
- For entry of OPERATING DATA - see chapter
07.05.2.

MANUAL
******
F4
10.03.00
SETUP MODE:
13:34:57
DOSING-kg-DIAGRAM
MANUAL
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

OPERATING MANUAL
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
INFO
multi-function key
OPERAT. REFERENCDATA
VOLUMES
F5 .
F1
F2
F3
F4
F5
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
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

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

Reference-Dosing-Volumes (RDVs)
10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
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
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
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
= 1

Press key
F 5 = DOSING
The display changes to query status (F5STATUS),

establishing
whether
the
WESTOMAT and the DCM are ready for
injection:

the DCM die is closed in position MANUAL.

= 0

BACK POSITION !
completely !
To DOSING by HAND:
I-19 DIE CLOSES (DCM) ............. = 1
MANUAL POSITION!
INFO
DOSING
SETUP MODE
Kg-DIAGRAM

OPERATING MANUAL
6-8
07.05.1
07051-B.doc

MANUAL
Version: 03.00 B
DOSING CONTROL
10.03.00
HEATING
SETUP MODE:
13:34:35
SCAN=CELL
REFERENCE-VOLUMES
To DOSING by HAND:
I-19 DIE CLOSES
(DCM) ........... = 1
I-20 DIE CLOSED-1 (DCM) ........... = 1
I-21 DIE CLOSED-2 (DCM) ........... = 1
MANUAL POSITION!

- Press and hold the external key DOS-ON to
activate TOP-STOP.

To DOSING by HAND:
External key DOS-ON has been pressed and

TOP-STOP is activated.
TOP-STOP = activate
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
t6
t7
DCM-DIE
TS=
DC
t2
RDV-01: NC=
AC=
t3=
t4=
t3
t4
t5

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
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
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:
- OPEN DIE and
- ADVANCE PLUNGER !
INFO
DOSING

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

OPERATING MANUAL
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
_K21. REFERENCE-kg-DIAGR. 65/21-NO 1:
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:
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

save):
F1
MEMO and:
MEMORY = YES:
F3
DOSING
MEMORY = NO:

10.03.00
SETUP MODE:
13:34:54
REFERENCE-VOLUMES
F5 - BACK TO ENTRY
F5
BACK TO ENTRY:

displayed;
additional
entries
and
The setup procedure for the REFERENCE-VOLUMES

is now completed.
Press key
press key
STATUS
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
***BASIC STATUS***
10.03.00 HEATING
13:34:57 SCAN=CELL
DOS. PIPE 65/21mm
!

P r o D o s
03.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
DOSING
F2
SETUP MODE:
F3
F4
F1
multi-function key
F 2 = SETUP

F5
10.03.00
13:34:57
F = MENU / ESC=back

F1: LOG DATA ......................
F4: kg-DIAGRAM ....................
LOG
DATA
=
=
=
=
=
1
1
1
1
1

FILL
LDTkg-DIA- REGULAT.
LEVEL
SETUP
GRAM
HEATING
F2
F3
F4
F5

multi-function key
F4 .
SETUP MODE
Kg-DIAGRAM

OPERATING MANUAL
OPERATING DATA
07.05.2
07052-B.doc
2-6
Version: 03.00 B
DOSING CONTROL
ATTENTION

ALWAYS
COMPLY
WITH
SAFETY
in the log (K 12).
F4


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
MANUAL
******
F4
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
MANUAL

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 .

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
3-6
07.05.2
If two different dosing pipes have been entered

in the LOG, the respective dosing pipe must be
selected here.

by pressing
12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
or
line
place cursor in dosing pipe
and press key
- 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

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

LOG, continue with:
- MODIFY to extend the dosing volume
range, or
-
K22. OPERATION-kg-DIAGR. 65/21 mm-NO 1:

F4 = MODIFY DATA
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

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

save):
F1
MEMORY = NO:

F5
DOSING CONTROL
12.10.99
HEATING
SETUP MODE:
13:34:34
SCAN=CELL
kg-DIAGRAM-INPUT
=
DATA
LOG
/
ESC=back

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:
F3
MEMO and:
Version: 03.00 B
BACK TO ENTRY:

displayed;
additional
entries
and
The setup procedure for OPERATING DATA (transfer

of REFERENCE DATA) is now completed.
Press key
status
press key
STATUS
21.03.99
SETUP MODE:
13:34:54
kg-DIAGRAM-INPUT
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
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

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

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):

21.03.99
SETUP MODE:
13:34:54
kg-DIAGRAM-INPUT
F1
F5 - BACK TO ENTRY
MEMORY
= YES
MEMORY
= NO
BACK TO
ENTRY
F1
F2
F3
F4
F5
MEMORY = NO:

F5
MEMORY = YES:
F3
MEMO and:
BACK TO ENTRY:

displayed;
additional
entries
and
SETUP MODE
Kg-DIAGRAM

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
press key
STATUS
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
!

P r o D o s
10.03.00
INFO
F1

SETUP
OPERAT. kg-DOS:
MODES
NEW
F2
F3
F4
F5

Dosing Control

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dosing Control

Uploaded by

Copyright:

Available Formats

WESTOMAT

AUTOMATIC DOSING UNIT for ALUMINIUM

WESTOMAT P ro Dos DPC

ST RIKO W EST O F EN GmbH

Diese Dokumentation ist urheberrechtlich geschtzt und darf nur zu internem

WESTOMAT ProDos DPC

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

P ro D os DPC - WESTOMAT CONTROL

OPERATIONAL FUNCTIONS - GENERAL

DOSING VOLUME (DATA SHEET)

DOSING VOLUME NEW / CORRECTION

INTERFACE: WESTOMAT - DCM

STRUCTURE OF OPERATOR INTERFACE

DOSING OPERATION (ON / OFF)

SWITCHING DOS ON- / OFF - GENERAL

LDT: LANGUAGE / DATE / TIME

SWITCHING THRESHOLD (of lamps)

CELL-FILLING LEVEL SYSTEM - GENERAL

HPDE-FILLING LEVEL SYSTEM - GENERAL

WESTOMAT ProDos DPC

ProDos DPC - WESTOMAT CONTROL

The Pro Dos DPC control is a compact,

integrated power supply unit for the supply with

integrated analog modules for the control of a

integrated temperature regulator for temperature

pluggable terminals for all electric connections

data transmission interface for remove diagnosis

data transmission interface for the loading of

protective cover at the rear side

back-lit LC display for the visualisation and

eight-segment display of desired and actual

five multi-function keys (below display ; the

eight help menu keys (availability indicated by

The Pro Dos DPC is equipped with the following

Pro Dos DPC - the WESTOMAT Control

Integral calculation of the dosing process for

Options for dosing contact (DC): by means of

Input menu for adjustment of dosing volume

Modification menu for selective modifications of

Proven and standardised signal interface

Automatic optimisation system for cycle

TEMPERATURE REGULATION SYSTEM:

Monitoring of parameter-controlled quality

Monitoring of parameter-controlled limit values

Monitoring of furnace temperature

EMERGENCY HEATING programme, to be used

Programmable weekend temperature reduction

Automatic warm-up programme for cold start of

FURNACE FILLING LEVEL INDICATION:

Filling level scanning options: by means of load

Five indicator lamps, which can be programmed

WESTOMAT P ro Dos DPC

WESTOMAT ProDos DPC

Pro Dos DPC - the WESTOMAT Control System

To be used during commissioning and for the

LOG data of all setup procedures with

Setup of temperature regulators with plantspecific parameters

Setup of filling level indication and rate of

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

Setup of time, date and language of user

SETTINGS MAY ONLY BE MADE BY QUALIFIED

The SETUP mode can be protected against

Setup for selection of operating modes for

THESE SETTINGS MAY ONLY BE MADE BY

* WESTOMAT - DOSING CONTROL *

* WESTOMAT - DOSING CONTROL *

* WESTOMAT - DOSING CONTROL *