AUTOMATION D2-FILL filling module

AUTOMATION DIRECT D2-FILL Filling Module

Product Description

Detailed Parameters

1. Control Specifications
   • Channels: 1 independent filling channel.
   • Measurement Modes: Volumetric (via flow meters), gravimetric (via load cells), or time-based (for fixed pumps).
   • Accuracy: ±0.1% of full scale (with calibrated sensors).
   • Resolution: 0.001 units (configurable based on application).
   • Max Filling Rate: Up to 10,000 units per cycle (adjustable via configuration).
2. I/O Interface
   • Analog Inputs: 2 × 12-bit analog inputs (0-10V, 4-20mA), for flow meters or load cells.
   • Digital Inputs: 4 × sinking inputs (24VDC), for start/stop commands, batch complete, etc.
   • Digital Outputs: 4 × relay outputs (2A/250VAC), for pump control, valve actuation, and alarms.
   • Communication: Built-in Modbus RTU (RS-485) for integration with HMIs or SCADA systems.
3. Electrical Characteristics
   • Power Supply: 24VDC ±10% (external power required).
   • Power Consumption: ≤5W.
   • Isolation: 500VAC between I/O channels and logic circuits.
4. Environmental Parameters
   • Operating Temperature: 0°C to 50°C (32°F to 122°F).
   • Storage Temperature: -20°C to 70°C (-4°F to 158°F).
   • Humidity: 5-95% RH (non-condensing).
   • Vibration Resistance: 10-57Hz, 0.75mm double amplitude (IEC 60068-2-6).
5. Physical Features
   • Dimensions: 110mm (L) × 76mm (W) × 30mm (H).
   • Weight: ~180g.
   • Mounting: DIN rail compatible.
   • LED Indicators: Status LEDs for power, filling in progress, batch complete, and errors.

Product Advantages and Features

1. Specialized Filling Algorithms
   Built-in PID control and overshoot compensation ensure precise filling, even with viscous liquids or rapid valve actuation.
2. Flexible Measurement Options
   Supports multiple measurement methods (volumetric, gravimetric, time-based) to accommodate different materials and process requirements.
3. Batch Management
   Stores up to 100 batch recipes with configurable parameters (target volume/weight, fill speed, pre-close offset).
4. Real-Time Monitoring
   Provides instant feedback on fill status, batch counts, and process metrics via integrated LEDs and Modbus communication.
5. Easy Integration
   Seamlessly integrates with DL205 PLCs and Automation Direct’s DirectSoft software for simplified programming and configuration.

Application Areas

1. Food & Beverage
   Filling of liquids (e.g., juices, oils), granular products (e.g., sugar, flour), and semi-solids (e.g., creams).
2. Pharmaceuticals
   Precise dosing of medications, vaccines, and laboratory reagents.
3. Chemical Processing
   Accurate dispensing of solvents, additives, and specialty chemicals.
4. Cosmetics
   Filling of lotions, shampoos, and perfumes into containers of various sizes.
5. Bottling & Packaging
   High-speed filling of bottles, cans, and pouches in packaging lines.

Precautions

1. Sensor Calibration
   • Regularly calibrate flow meters or load cells to maintain accuracy.
   • Use the module’s built-in calibration wizard for precise sensor setup.
2. Material Compatibility
   • Ensure external valves and pumps are compatible with the material being filled (e.g., corrosion resistance for chemicals).
3. Electrical Installation
   • Properly ground the module and all connected equipment to prevent electrical interference.
   • Use shielded cables for analog inputs to reduce noise.
4. Maintenance
   • Periodically inspect valves and pumps for wear or blockages.
   • Clear batch data and reset counters when switching between different products.
5. Safety Interlocks
   • Implement emergency stop circuits and overfill protection to ensure safe operation.
   • Use the module’s fault detection features (e.g., flow sensor failure alarms).