SF Series Additive Feeders
Part No.: 882.00274.00
Bulletin No.: BF2-605.1
Effective Date: 5/2/08
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2008
All rights reserved.
Table of Contents
CHAPTER 1: SAFETY................................................................V
1-1
How to Use This Manual ............................................................................................. v
Safety Symbols Used in this Manual.....................................................................v
Warnings and Precautions ......................................................................................... vi
Responsibility .............................................................................................................vii
General Responsibility......................................................................................... vii
Operator Responsibility.......................................................................................viii
Additive Feeder Safety Tags................................................................................ ix
Maintenance Responsibility.................................................................................. ix
Reporting a Safety Defect .....................................................................................x
1-2
1-3
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................11
2-1
2-2
2-3
Models Covered in This Manual................................................................................11
General Description...................................................................................................11
Standard Features.....................................................................................................11
Mechanical Features...........................................................................................11
Electrical Features...............................................................................................12
Controller Features..............................................................................................12
Options......................................................................................................................12
Accessories...............................................................................................................13
Safety Devices and Interlocks...................................................................................13
2-4
2-5
2-6
CHAPTER 3: INSTALLATION..................................................15
3-1
3-2
3-3
3-4
Uncrating the Equipment...........................................................................................15
Rigging and Placing the Additive Feeder ..................................................................15
Electrical Connections...............................................................................................16
Setup Procedures......................................................................................................17
Determining the Desired Feed Rate....................................................................17
Calibration Procedure..........................................................................................19
Initial Start-up ............................................................................................................21
Pre-Startup Checks.............................................................................................21
Starting Up the Additive Feeder ..........................................................................21
Shutting Down the Additive Feeder.....................................................................21
3-5
CHAPTER 4: OPERATION.......................................................22
4-1
4-2
Start-up......................................................................................................................22
Controller Description and Operation........................................................................22
Identifying Control Panel Indicator Lights and Switches on the Controller..........22
Timer/Counter Control Operation (Injection Molding Applications) .....................22
Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications)..............23
Injection Molding Applications...................................................................................24
Steps that must be completed before the additive feeder will perform properly:.24
Injection Molding .................................................................................................24
Control Relay Connection ...................................................................................24
Field Control Programming..................................................................................24
4-3
Additive Feeders
iii
Resetting the Unit to Un-Programmed State.......................................................25
JP1 (Program Enable Jumper)............................................................................25
Programming Step by Step Guide.......................................................................25
Injection Mode Application Notes........................................................................27
Extrusion Applications...............................................................................................28
Steps that must be completed before the additive feeder will perform properly:.28
Extruder Tracking Control ...................................................................................28
Control Relay Connection ...................................................................................28
Extruder Tracking Installation and Setup.............................................................29
Field Control Programming..................................................................................30
Resetting the Unit to Un-Programmed State.......................................................31
JP1 (Program Enable Jumper)............................................................................31
Programming Step by Step Guide.......................................................................31
Extruder Tracking Control Application Notes.......................................................32
4-4
CHAPTER 5: PROGRAM PARAMETER DESCRIPTIONS .....34
5-1
Defining Program Parameters...................................................................................34
CHAPTER 6: MAINTENANCE .................................................39
6-1
6-2
Preventative Maintenance Schedule.........................................................................39
Preventative Maintenance.........................................................................................40
Material Cleanout/Changeover............................................................................40
Corrective Maintenance ............................................................................................41
Auger Assembly Changeover..............................................................................41
Motor Brush Replacement...................................................................................42
6-3
CHAPTER 7: TROUBLESHOOTING .......................................43
7-1
Introduction................................................................................................................43
CHAPTER 8: APPENDIX..........................................................46
8-1
Technical Specifications............................................................................................46
Annex B Information............................................................................................46
Drawings and Diagrams............................................................................................47
Spare Parts List.........................................................................................................49
Returned Material Policy ...........................................................................................52
Credit Returns .....................................................................................................52
Warranty Returns ................................................................................................52
Safety Tag Information..............................................................................................52
Additive Feeder Safety Tags...............................................................................52
Additive Feeder Identification (Serial Number) Tag ..................................................53
Technical Assistance.................................................................................................54
Parts Department ................................................................................................54
Service Department.............................................................................................54
Sales Department................................................................................................54
Contract Department...........................................................................................54
8-2
8-3
8-4
8-5
8-6
8-7
Additive Feeders
iv
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
additive feeder. The purpose is to assist you in applying efficient, proven techniques that
enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the additive feeder. We can also provide the assistance of a factory-trained technician to
help train your operator(s) for a nominal charge. This section includes instructions, checks,
and adjustments that should be followed before commencing with operation of the additive
feeder. These instructions are intended to supplement standard shop procedures performed
at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the additive feeder safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your additive feeder provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.
Additive Feeders
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1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power before servicing or maintaining the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; DO NOT use the additive feeder in an explosive atmosphere.
; DO NOT use additive feeder outdoors or in wet environments. Moisture will
damage the motor and can create an electric shock hazard.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Use EXTREME CAUTION when working with additive feeder. NEVER put
hands or tools in or near the auger assembly when power is connected.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
Additive Feeders
Chapter 1: Safety
vi
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
Additive Feeders
Chapter 1: Safety
vii
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator usually has
the most daily contact with the equipment and intimately knows its capabilities and
limitations.
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation procedures. Cooperate with co-workers to promote safe
practices. Immediately report any potentially dangerous situation to your supervisor or
appropriate person.
REMEMBER:
• NEVER place your hands or any part of your body in any dangerous location.
• NEVER operate, service, or adjust the feeder without appropriate training and first
reading and understanding this manual.
• NEVER try to pull material out of the feeder with your hands while it is running!
• Before you start the feeder check the following:
• Remove all tools from the feeder;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
hopper area;
• If your feeder has been inoperative or unattended, check all settings before starting the
unit.
• At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,
or remove safety guards. Such alteration is not only unsafe, but will void the warranty
on your equipment.
• When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
• Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual feeder action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble into the feeder
while working on it.
• DO NOT wear loose clothing or jewelry, which can be caught while working on a
feeder. In addition, cover or tie back long hair.
Additive Feeders
Chapter 1: Safety
viii
• Clean the feeder and surrounding area DAILY, and inspect the machine for loose,
missing or broken parts.
• Shut off power to the feeder when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.
Additive Feeder Safety Tags
Read Operation
and Installation
Manual
Shear Hazard
Rotating Auger
High Voltage
Earth Ground
Inside Enclosure
PE Protected Earth
Ground
Lifting Point
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on equipment above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your
equipment, use it. The work platform should have secure footing and a place for tools and
parts. DO NOT climb on equipment, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
Additive Feeders
Chapter 1: Safety
ix
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the equipment until all persons are clear of the area. DO NOT start
and run the machine until you are sure all parts are functioning correctly.
BEFORE you turn the machine over to the operator for production, verify all equipment
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
Additive Feeders
Chapter 1: Safety
x
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 1 and 2
component additive feeders. Model numbers are listed on the serial tag. Make sure you know
the model and serial number of your equipment before contacting the manufacturer for parts
or service.
Our additive feeders are designed to precisely feed up to two components before being used
in the injection molding, blow molding or extrusion processes. Additive Feeders are
configured to meet the specific requirements stated by the Customer at the time of purchase.
2-2 General Description
Our additive feeder is a highly accurate unit designed to feed one or two additives into a
stream of virgin plastic pellets prior to injection molding, blow molding, or extrusion. Such
additives may include color, regrind, or other free-flowing pelletized or granular materials.
The additive feeder may also be appropriate for other applications. Consult the manufacturer
for additional information.
2-3 Standard Features
Mechanical Features
Transport Tube
• Stainless steel augers available in ½”, ¾”, 1”, 1-1/4” and 1-1/2” sizes
• Augers/insert assemblies are interchangeable without tools
• UHMW polyethylene auger insert is durable and easily cleaned
• Calibration hatch opens without tools
• Cleanout hatch below the flood zone opens without tools and allows the supply hopper
to dump completely.
• Lightweight aluminum casting
Main Throat
• Low profile design adds only 6 inches to supply system headroom requirements
• Accommodates one or two additive feeders
• Sturdy steel construction with sight glasses to visually confirm proper operation
Supply Hopper
• 1 or 2 cubic-foot capacity
• Design based on dynamic/static material flow characteristics
• Angled hopper geometry allows use with 60º machine supply hoppers
• Easy, fast, and complete cleanout
• Sight glasses give visual level indication
• Manual fill cover standard
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Chapter 2: Functional Description
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Motor Assembly
• Quick release swing-away motor mount speeds auger/motor changes and cleanout
• Permanently lubricated
• Replaceable motor brushes
Electrical Features
Motor Assembly
• Continuous service fractional horsepower DC motor.
• Hall Effect sensor transmits RPM to microprocessor control
• 115/1/60 supply voltage
Controller Features
• Closed-loop control constantly monitors feedback from the auger motor RPM sensor
for high accuracy and repeatability. Feed rates remain stable during main power
supply voltage fluctuations.
• Remote control mounting capability permits mounting the control panel up to 9 feet
from the feeder.
• Field-programmable display permits viewing in rpm, pounds per hour, kilos per hour,
etc., as well as high/low limits.
• Automatic and manual/calibration operation modes.
2-4 Options
Special Voltage
• 230/1/60 VAC
Timer/Counter Control
• Designed for use with cycled processes like injection molding
• Cycle timer can be set to limit the additive feeder cycle to avoid feeding straight color
if a resin supply problem occurs in conjunction with a processing machine control
relay failure.
• Batch counter provides inventory management information
• Calibration feature allows precise, repeatable sampling during setup
Timer/Elapsed Timer Control
• Designed for use with continuous processes like extrusion
• Elapsed timer provides inventory management information
• Calibration feature allows precise, repeatable sampling during setup
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Extruder Following Feature
• This feature allows the additive feeder to automatically increase or decrease the
material feed rate as the extruder screw speed changes.
Quick Change Supply Hopper
• 0.3 cubic foot capacity hopper with slide gate allows for rapid change of additives
Supply Hopper Covers
• Hopper mounting cutout for vacuum receivers
• Hopper loader mounting cutout for hopper loaders
• Blank cover available for custom cutout
Additional Auger Assemblies
• Switch augers for changing process throughputs
Mounting Adapters
• Special main throat and flanges can eliminate transitions and accommodate different
machine hoppers
2-5 Accessories
Low Level Alarm
• Audible/visual alert to allow supply hopper level to avoid feeding straight resin into
the processing machine
• Remote mount
• Advisory or process interrupt capability
• Alarm silence/acknowledge button
Drawer Magnet
• Removes tramp metal from the process stream
2-6 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
additive feeder. This manual is not intended to supersede or alter safety standards established
by the user of this equipment. Instead, the material contained in this section is recommended
to supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
•
•
•
Identify and locate specific safety devices.
Understand the proper use of the safety devices provided.
Describe the function of the safety device.
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Chapter 2: Functional Description
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Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel
from dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the additive
feeder; however, it is the responsibility of the personnel operating and maintaining the
equipment to familiarize themselves with the safety procedures and the proper use of any
safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on these additive feeders are primarily concerned with electrical power disconnection
and the disabling of moving parts that may need to be accessed during the normal operation
of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these additive feeders are equipped with a line
cord plug. This allows the operator or maintenance personnel to unplug the additive feeder
from its power source and tag it out. The plug can then be tagged with any number of
approved electrical lockout tags available at most electrical supply stores.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the additive feeder. Failure to do so may result in
serious injury. No one but the person who installed the lockout may remove it.
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Chapter 2: Functional Description
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Chapter 3: Installation
3-1 Uncrating the Equipment
Additive feeders are shipped mounted on a skid, and enclosed in a cardboard box.
1. Pry the crating away from the skid.
Note: Remove the nails holding the box to the skid and lift the box
off carefully; avoiding staples in the 1’ x 4’ wood supports.
Cut the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the skid
from the unit.
3-2 Rigging and Placing the Additive Feeder
Note: Disassemble the material transport assembly from the main throat to
ease marking, drilling and installation of the additive feeder.
If the machine throat is smaller than the additive feeder throat,
adapters are available.
1. Remove hopper from your processing machine.
2. Drill holes in both flanges of the additive feeder main throat to exactly match
the bolt hole pattern on your processing machine throat. Select a position for
easy operator access.
3. Bolt the main throat to the machine, and the machine hopper to the main throat
with the appropriate bolts, nuts and lockwashers.
4. Mount the control in a position with convenient operator access near the
additive feeder. Avoid locations with excessive dust, vibration and moisture.
Supply System Installation
If the additive feeder is to be used with an automatic loading system, install the hopper
loader, vacuum hopper, etc., in the supply hopper cover. Follow the instructions provided
with the loading system.
Additive Feeders
Chapter 3: Installation
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3-3 Electrical Connections
When making electrical connections to your additive feeder, ensure that you take into
consideration and make arrangements for the following:
• A qualified electrician should make all electrical connections.
• Fulfill all national, state, and local safety and electrical code requirements.
• The serial tag lists voltage, phase, and amp draw information
• Line voltage must be within plus or minus ten percent (±10%) of the voltage listed on
the serial tag, or damage may occur.
• Install a fused disconnect with a lockout feature in the power main leading to the
additive feeder if the unit will be wired directly to a power main.
• Make sure all electrical connections are tight.
Main Power Connection
The control is shipped pre-wired and attached to the additive feeder. Standard controls are
supplied with a power cord with the plug wired to the control unit, ready to plug into an
appropriately grounded three-prong receptacle.
Control Relay Connection
To interlock the additive feeder operation to an injection molding machine, extruder, etc.,
remove jumper (J1) from the terminal block in the control enclosure and wire in the control
relay signal from the processing machine. For injection applications the additive feeder will
automatically operate at the specified rate while the screw is turning.(see 4-3, Injection Mode
Application), for extrusion processes the additive feeder will run proportional to the speed of
the extruder. (See 4-4, Extrusion Mode Application)
Please refer to the schematics enclosed in the information packet for the latest electrical
drawings.
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3-4 Setup Procedures
This section provides the procedures necessary for configuring your additive feeder.
Configuration of your additive feeder includes determining the desired feed rate and
calibrating the additive feeder. We recommend that you carry out these procedures in the
order given here.
Note: Before carrying out these procedures, install all equipment as
described in this section.
Determining the Desired Feed Rate
The additive feed rate is the desired amount of additive to be introduced into the process
stream per hour. To determine the feed rate, follow the procedure in this section. If the
desired feed rate is known, go to the calibration procedure in the next section. The charts in
figures 1 and 2 on the following page provide conversion and rate charts to assist you in your
calculations.
For Cyclical Processing (Injection Molding, etc.)
To set up an additive feeder for cyclical processing, you need to know shot size, recovery
time, and the letdown ratio.
Cyclical Processing Equation:
Shot Size (oz)
Recovery time (sec) x Letdown (ratio or %) x 225 = Feed Rate (lbs./hr.)
Example:
Shot size = 8 ounces
Recovery time = 5 seconds
Letdown ratio = 20:1
8 oz./5 sec. X 1/20 = 0.08 = Desired feed rate
To convert to lbs./hr.: 0.08 oz/sec x 225 = 18 lbs./hr.
For Continuous Processing (Extrusion, etc.)
To set up an additive feeder for continuous processing, you need to know the total process
throughput and the desired additive percentage or letdown ratio.
Continuous Processing Equation:
Total throughput (lbs./hr.) x percentage of additive = Feed rate
Example:
Total throughput = 100 pounds per hour
Percentage of additive = 2%
100 lbs./hr. x 0.02 = 2 lbs./hr. feed rate
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Figure 1: Conversion Chart
Multiply
Ounces per Second
Grams
Ounces
Seconds
By
To obtain
Pounds per Hour
Ounces
Pounds
Hours
225
0.035
0.0625
0.00028
Figure 2: Rate Chart
110 lb/hr
110
100
90
80
70
60
50
40
30
20
10
0
55 lb/hr
25 lb/hr
7 lb/hr
4 lb/hr
7 lb/hr
1 1/2 lb/hr
3/4" auger
1/2 lb/hr
1/2" auger
1" auger
1 1/4" auger
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Chapter 3: Installation
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Calibration Procedure
This procedure allows the operator to precisely adjust additive feed rates.
Caution!
Never put hands or tools in or near the auger assembly when power is
connected.
Do not wear gloves or loose clothing during calibration. The auger is
exposed when the calibration or cleanout hatches are open.
Equipment Needed:
• Scale
• Sample container
• Timer- stopwatch, watch/clock w/second hand
Procedure
1. Close cleanout and calibration hatches.
2. Fill the additive supply hopper.
3. Weigh the empty sample container.
4. Swing open the calibration hatch near the main throat.
5. Set the controller to a desired RPM.
6. Place the sample container below the calibration hatch.
7. Hold the three-position motor switch in the Manual position for about a minute.
This lets the new setpoint stabilize and fills the auger flights with material. Discard
the first sample.
8. Position the empty scale container below the calibration hatch and hold the three-
position motor switch in the Manual position for exactly one minute.
Note: If your additive feeder is equipped with the timer option, set the timer to
one minute and put the three-position switch in the Manual position.
Operation will automatically stop after one minute.
9. Weigh the sample container. Subtract the weight of the container and multiply by
60 to determine the pounds per hour feed rate.
10. Adjust the auger rpm and repeat the calibration process until the desired feed rate is
achieved.
Note: To speed the calibration procedure, reduce trial and error auger rpm
settings and zero in on the desired feed rate. Chart the calculated feed
rates from a few rpm settings on graph paper. Draw a straight line
between the coordinates to establish a customized feed rate curve for
the actual operating conditions. A sample graph is provided on the
next page; graph paper is included in the back of this manual for use
with your feeding processes.
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Examples:
This example shows how to extrapolate a desired feed rate of 3 lbs./hr., based on the feed
rates of 3 trial rpm settings.
Observed Feed Rates
Sample 1 = 2 pounds per hour @ 20 rpm
Sample 2 = 4 pounds per hour @ 40 rpm
Sample 3 = 6 pounds per hour @ 60 rpm
In this example, a feed rate of 3 lbs./hr. would be about 30 rpm.
8
Calculated 7
feed rates
(lbs/hr)
@ the
3
6
5
4
3
2
1
0
2
trial RPM
4
1
10 20 30 40 50 60 70
Trial RPM settings
0
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Chapter 3: Installation
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3-5 Initial Start-up
Pre-Startup Checks
; Are all the electrical connections correct, secure and to code?
; Is the auger insert locked in place?
; Are the motor and auger properly coupled and the motor mount locked in place?
; Are the cleanout and calibration hatches shut and secured?
; Are all tools, hardware, etc., cleared from the feeder?
; Is the processing machine ready for operation?
; Is the control relay connection to the processing machine properly installed?
; Is there an adequate supply of additive in the supply hopper?
; Is the supply system (if installed) ready for operation?
Starting Up the Additive Feeder
1. Turn the power switch ON.
2. Set the desired feed rate on the RPM display using the up or down arrows.
3. Flip the motor switch to AUTO.
If the additive feeder is installed correctly, it should begin operation at the desired RPM when
the processing machine screw is in operation.
Shutting Down the Additive Feeder
1. Flip the motor switch to the OFF (center) position.
2. Turn the power OFF.
For long term shutdown, disconnect power and clean the additive feeder.
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Chapter 4: Operation
4-1 Start-up
1. Turn the power switch ON.
2. Set the desired feed rate on the RPM display using the up or down arrows.
3. Flip the motor switch to AUTO.
If the additive feeder is installed correctly, it should begin operation at the desired RPM when
the processing machine screw is in operation.
4-2 Controller Description and Operation
Identifying Control Panel Indicator Lights and Switches on the Controller
Switches
Power Switch. This switch turns the control ON and OFF.
Motor Switch. This switch has three (3) positions:
• OFF stops the auger motor.
• AUTO starts normal automatic operation.
• MANUAL operates the auger at the set point as long as the switch is held in this
position. Use this feature when calibrating the feeder or during cleanout.
Indicator Lights
Motor Light. This indicator lights when the auger motor is turning.
Auger Speed. This LED displays the auger speed setpoint.
Timer/Counter Control Operation (Injection Molding Applications)
The Timer/Counter control is designed for use with cyclical processes like injection molding
and features a timer and counter module. It also acts as a cycle override safety timer.
Timer Module
This feature of the controller assists in calibration of the additive feeder (See Page 19 for
specific calibration instructions).
Procedure
1. Set the timer to the desired calibration period, using the round timer keys (See the
timer information sheet for additional information).
2. Start the additive feeder by flipping the MOTOR switch to the MANUAL position.
3. When the timer times out, the feeder automatically stops.
Used as a Cycle Override Safety Timer
This component of the controller allows the operator to override the molding machine shot
cycle when the additive feeder motor is running in AUTO mode.
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Procedure
1. Time the duration of feeder operation during a typical Injection molding machine
shot cycle.
2. Set the timer to a slightly longer value.
3. Start the additive feeder by flipping the motor switch to the AUTO position.
4. If the timer times out because of a process flow problem, the feeder will
automatically stop.
5. Reset the power switch.
Counter Module
The counter module may be used as an inventory management aid and can also confirm the
total cycles between reset independent of the IMM’s control. Every IMM cycle will
increment the display value. The counter module has battery-backed memory and will not
lose count if the electrical power is interrupted.
• Press the RESET button to reset the counter.
Note: Remove the jumper on the back of the module to lock out the reset
button. Replace the jumper to restore reset button operation.
Disconnect the power before moving the jumper.
Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications)
The Timer/Elapsed Timer control is designed for use with continuous processes like
extrusion and blow molding and features a timer and elapsed time module.
Timer Module
This feature of the controller assists in calibration of the additive feeder (See Page 19 for
specific calibration instructions).
1. Set the timer to the desired calibration period, using the round timer keys (see the
timer information sheet for additional information).
2. Start the additive feeder by flipping the motor switch to the MANUAL position.
3. When the timer times out, the feeder will automatically stop.
Elapsed Time Module
The elapsed time module may be used as an inventory management aid for continuous
processing operations.
The timer module measures the time the additive feeder control receives the monitored
control relay signal from the extruder/blow molder machine. The timer module has a battery-
backed memory and will not lose the elapsed time of operation if the electrical power is
interrupted.
• Press the RESET button to reset the counter.
Note: Remove the jumper on the back of the module to lock out the reset
button. Replace the jumper to restore reset button operation.
Disconnect power before moving the jumper.
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4-3 Injection Molding Applications
Discussed in this portion of the manual are the finer points of the additive feeder operation,
programming the control, and installation notes and examples. If you are unfamiliar with this
product or have never performed this type of installation, please read this section of the
manual fully before installing the equipment.
Steps that must be completed before the additive feeder will perform properly:
–
–
The proper control signal from the injection process
Accurate programming of the control (Factory default programming is sufficient for most
injection applications)
Injection Molding
Injection Molding cycles require that the additive feeder supply a constant feed rate during
recovery and no material during the shot. Once a desired feed rate has been identified (See 3-
4, Determining the Desired Feed Rate) and a calibration has been performed (See 3-4,
Calibration Procedure), then the correct RPM can be set for that process. Finally the additive
feeder needs to be told when to start and stop feeding material using a control connection.
Control Relay Connection
To interlock the additive feeder operation to an injection molding machine, remove jumper
(J1) from the terminal block in the control enclosure and wire in the control relay signal from
the processing machine. For injection applications the additive feeder will automatically
operate at the specified rate while the screw is turning.(see 4-3, Injection Mode Application)
Field Control Programming
Although the drive’s user interface is very versatile, it is also simple to setup and operate.
With just a few button presses, it allows the user to configure a number of adjustable
parameters. The LED display has three basic operating modes: Running Mode, Parameter-
Selection Mode, and Value Mode. Each of the three modes have specific visual indicators
that allow the user to immediately determine the current state or mode of the user interface.
Note: Parameter-Selection Mode and Value Mode can only be entered if the Program
Enable jumper is in the “On” position.
Running Mode is the default display of the unit when power is applied. The drive will spend
the majority of its time in this mode. In Running Mode, the display shows the target value in
the appropriate user defined format of rate, time, or percentage. The control will
continuously attempt to drive the motor at the requested target rate. In this display mode, the
Up and Down buttons increase or decrease the displayed target value until either the display
minimum or display maximum limit is reached. Depending on the alarm configuration, these
buttons may also serve as an alarm-silence or alarm-reset button.
Parameter-Selection Mode can be entered by simply pressing and holding the Enter button
down for three seconds. Once in Parameter-Selection Mode, the far left of the display will be
a “P.” The right side of the display will indicate the currently selected parameter number for
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editing purposes. Pressing the Up or Down button will increase or decrease the selected
parameter number on the display. Although the parameter numbers are in numerical order,
some numbers are skipped. These numbers represent reserved parameters that are not yet
implemented and are not displayed. Once the desired parameter number is displayed, a press
of the Enter button will change the display to the Value Mode.
Note: When in Parameter-Selection Mode, pressing the Enter button with parameter
0 selected will cause the unit to return to Running Mode.
Value Mode is used to modify the value of the selected parameter. When in Value Mode, the
two dots which form the colon, between digits two and three, will alternately flash (one, then
the other) to inform the user that a parameter’s value is being edited. Pressing the Up or
Down button increases or decreases the selected parameter’s value. See the default value
tables (below) for the list of preprogrammed values. Value changes take effect immediately.
Once the desired value is showing in the display window, pressing the Enter button again will
return to Parameter Selection Mode. The new value is not saved in permanent memory until
the Enter button is pressed. Removing power from the unit while in Value Mode may result
in the specified new value being lost.
Resetting the Unit to Un-Programmed State
The factory-default settings can be easily restored using either of two methods. Both
methods require the Program Enable jumper to be in the “On” position. The first is to apply
power to the unit with both the Enter and Down buttons pressed for 3 seconds. The second is
to change the value of parameter 95 to 5.
JP1 (Program Enable Jumper)
The JP1 jumper is located under the dust cover on the back end of the upper board. When the
jumper is set to the "Off" position, all programming features are locked out to the front panel
user. When the jumper is in the "On" position, the programming parameters are open to
change. JP1 is shipped in the "Off" position.
Programming Step by Step Guide
1. Remove the power source from the controller. Following the procedures in
your facility, lockout or tagout the power source.
2. Remove the cover from the control enclosure
3. At the connection end of the drive lift the black plastic dust cover up slightly
then slide it out of the back of the drive.
4. Locate the jumper labeled “JP1.”
5. Move the JP1 jumper from the “OFF” position to the “ON” position.
6. Slide the black plastic cover back into position.
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7. Install the enclosure cover.
8. Remove any lockout/tagout devices in use as per procedures in place at your
facility, then connect the controller to the power source and power the unit
up.
9. Press the Enter button until parameter selection mode is entered. When the
drive is in Parameter-Selection Mode, the far left of the display will be a “P.”
10. Use the Up and Down arrow buttons to navigate to the desired parameter.
11. When the parameter number to be changed is displayed press the Enter
button to enter Value Mode. When in Value Mode, the two dots which form
the colon between digits two and three will alternately flash.
12. Use the Up and Down arrow buttons to change the parameter’s displayed
value.
13. Press the Enter button to return to Parameter-Selection Mode.
14. Use the Up and Down Arrow buttons to go to the next parameter to be
modified. Repeat as required for any remaining parameters.
15. When all program modifications are completed, use the Up and Down Arrow
buttons to go to parameter “0” then press the Enter button to return to run
mode.
16. Remove the power source from the controller. Following the procedures in
your facility, lockout or tagout the power source.
17. Remove the dust cover from the control enclosure.
18. At the connection end of the drive lift the black plastic cover up slightly then
slide it out of the back of the drive.
19. Locate the jumper labeled “JP1”.
20. Move the JP1 jumper from the “ON” position to the “OFF” position.
21. Slide the black plastic cover back into position.
22. Install the enclosure cover.
23. Remove any lockout/tagout devices in use as per procedures in place at your
facility, then connect the controller to the power source and power the unit
up.
The drive is now ready to be used.
The required programming values for Injection Mold Applications are located on
drawing number A0541236, one of three drawings that are included with the additive
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feeder. If you do not have these drawings contact service to have them forwarded to
you.
Injection Mode Application Notes
The additive feeder controller has the ability to display feed rates in units other than the
factory set auger RPM display. With proper programming, the feeder can display
pounds/hour, grams/minute, etc.
Programming for units other than auger RPM REQUIRES that the system be calibrated to
determine exactly how much material is delivered at specific RPMs. Please refer to the
Calibration Procedure section for additional details.
Please note that custom programming for units other RPM will only provide meaningful
results when the auger and sleeve size does not change, and when the materials to be fed have
similar physical characteristics.
Example 1: The unit is programmed by the end user to display feed rates in pounds/hour
with a ¾” auger and sleeve. Someone else replaces this auger and sleeve with a 1” diameter
unit and does not calibrate and reprogram the controller. The displayed values are no longer
valid.
Example 2: The unit is programmed by the end user to display feed rates in pounds/hour of
a pelletized colorant material. The pellets are of a uniform size and shape, freely flow, and
contain no extraneous materials. At some point the additive feeder is used to introduce
regrind material instead of the previous colorant pellets and does not calibrate and reprogram
the controller. The displayed values are no longer valid.
When the controller is to be programmed to display in units other than auger RPM,
parameters P20, P21, and P30 will need to be modified.
The value in parameter P20 must be programmed to the lowest desired delivery rate. The
value in parameter P21 must be programmed to the highest desired delivery rate, and the
value in parameter P30 must be programmed to a value that matches what the auger delivers
when it is operating at full speed (71 RPM).
Example 1: An end user wants the additive feeder to display how many ounces per second
are delivered rather than what speed the auger is to turn at. When the end user calibrated the
unit they determined that at 10 RPM the unit delivered 1 ounce per second, and at 71 RPM
the unit delivered 7.1 ounces per second. The end user wants to be able to set the control to
deliver between 2 and 5 ounces per second. The value in parameter P20 gets programmed to
“20” which will allow a minimum setpoint of 2.0. The value in parameter P21 gets
programmed to “50” which will allow a maximum setpoint of 5.0. The value in parameter
P31 gets programmed to “71” which is how much material is delivered when the unit is
rotating at full speed (71 RPM).
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4-4 Extrusion Applications
Discussed in this portion of the manual are the finer points of the additive feeder operation,
programming the control, and installation notes and examples. If you are unfamiliar with this
product or have never performed this type of installation, please read this section of the
manual fully before installing the equipment.
Steps that must be completed before the additive feeder will perform properly:
-The proper control signal from the extrusion process
-Accurate programming of the control
Extruder Tracking Control
The extruder tracking control option allows the additive feeder’s auger (follower) to turn in a
precise ratio to the speed of your extruder screw (master). The speed control on the feeder
can be set for any feed ratio from 10% to 200%.
The extruder tracking control detects the speed of the extruder screw and causes the feeder
screw to rotate at the desired RPM. In effect, the extruder tracking control acts as an
automatic speed control.
The extruder tracking control requires a 5 VDC TTL NPN RPM signal from the extruder.
Use an existing RPM signal from the extruder; consult with the extruder’s manufacturer for
the signal type and frequency.
You will need to know:
1. The signal voltage
2. The number of pulses per extruder screw revolution
A wide variety of sensors can be supplied by the manufacturer to suit your needs if the
extruder control circuit does not provide a suitable signal.
These sensors include:
• Inductive proximity sensors to sense gear teeth.
• Magnetic pickups to sense affixed magnets.
• Optic sensors to sense affixed reflective tape. (Included with extrusion tracking
control)
Consult your sales representative for additional information.
Control Relay Connection
To interlock the additive feeder operation to an extruder, remove jumper (J1) from the
terminal block in the control enclosure and wire in the control relay signal from the
processing machine. Connecting the additive feeder to the control relay simply ensures that
when the extrusion process stops so does the additive feeder. (Without this control
connection, the auger may continue feeding material for a short time).
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Extruder Tracking Installation and Setup
The additive feeder control is supplied with standard factory defaults. Control programming
is required to suit the requirements of your process (See page 24, Field Control
Programming).
Connect the TTL signal acquired from the extruder control or from a sensor you have
installed to the terminal strip as shown in the electrical schematics provided with your unit’s
installation packet.
1. Install the feeder as described in Chapter 3.
2. Calibrate the feeder as described on Page 18. Determine the feed rates at different
rpms. We recommend that you plot the feed rates on graph paper.
3. Calculate a new display constant taking the extruder screw signal into account.
Constant = 1000 x # of Pulses per Revolution of Extruder Screw ℵ
# of Pulses per Revolution of the Feeder Screw ℑ
ℵ If not counted directly from screw, multiply by a “fudge factor” to get the pulses per
extruder screw rpm.
ℑ Factory set at 843 (PPR x 28.1 gear ratio).
Program the control to the new constant, as described in the next section “Field Control
Programming.”
Determine the desired additive feeder setpoint (% of extruder (master) screw RPM). To
determine this, you must know:
• Total extruder feedrate (lbs./hr.).
• The RPM of the extruder screw at that feedrate.
• The letdown ratio of the additive (% or :).
• The additive feedrate required at that letdown ratio (total feedrate X
letdown ratio).
• The additive feedrate RPM needed to achieve this feedrate (as
determined by the calibration procedure).
Extruder Tracking Equation:
Set Point = (rpm of feeder / rpm of extruder) x 100
Example:
Total extruder feedrate = 500 pounds per hour
Extruder screw rpm for 500 lbs/hr = 50 rpm
Additive letdown percentage = 7%
Additive feedrate = 500 X 0.07 = 35 lbs./hr.
Feeder auger rpm needed for 35 lbs./hr. = 44 rpm (as the calibration procedure has
shown)
Assuming this, set point = 44 rpm/50 rpm x 100 = 88 or 88% of the extruder screw speed.
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Field Control Programming
Although the drive’s user interface is very versatile, it is also simple to setup and operate.
With just a few button presses, it allows the user to configure a number of adjustable
parameters. The LED display has three basic operating modes: Running Mode, Parameter-
Selection Mode, and Value Mode. Each of the three modes have specific visual indicators
that allow the user to immediately determine the current state or mode of the user interface.
Note: Parameter-Selection Mode and Value Mode can only be entered if the Program
Enable jumper is in the “On” position.
Running Mode
Running Mode is the default display of the unit when power is applied. The drive will spend
the majority of its time in this mode. In Running Mode, the display shows the target value in
the appropriate user defined format of rate, time, or percentage. The control will
continuously attempt to drive the motor at the requested target rate. In this display mode, the
Up and Down buttons increase or decrease the displayed target value until either the display
minimum or display maximum limit is reached. Depending on the alarm configuration, these
buttons may also serve as an alarm-silence or alarm-reset button.
Parameter-Selection Mode
Parameter-Selection Mode can be entered by simply pressing and holding the Enter button
down for three seconds. Once in Parameter-Selection Mode, the far left of the display will be
a “P.” The right side of the display will indicate the currently selected parameter number for
editing purposes. Pressing the Up or Down button will increase or decrease the selected
parameter number on the display. Although the parameter numbers are in numerical order,
some numbers are skipped. These numbers represent reserved parameters that are not yet
implemented and are not displayed. Once the desired parameter number is displayed,
pressing the Enter button to change the display to the Value Mode.
Note: When in Parameter-Selection Mode, pressing the Enter button with parameter
0 selected will cause the unit to return to Running Mode.
Value Mode
Value Mode is used to modify the value of the selected parameter. When in Value Mode, the
two dots which form the colon, between digits two and three, will alternately flash (one, then
the other) to inform the user that a parameter’s value is being edited. Pressing the Up or
Down button increases or decreases the selected parameter’s value. See the default value
tables (below) for the list of preprogrammed values. Value changes take effect immediately.
Once the desired value is showing in the display window, pressing the Enter button again will
return to Parameter Selection Mode. The new value is not saved in permanent memory until
the Enter button is pressed. Removing power from the unit while in Value Mode may result
in the specified new value being lost.
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Resetting the Unit to Un-Programmed State
The factory-default settings can be easily restored using either of two methods. Both
methods require the Program Enable jumper to be in the “On” position. The first is to apply
power to the unit with both the Enter and Down buttons pressed for 3 seconds. The second is
to change the value of parameter 95 to 5.
JP1 (Program Enable Jumper)
The JP1 jumper is located under the dust cover on the back end of the upper board. When the
jumper is set to the "Off" position, all programming features are locked out to the front panel
user. When the jumper is in the "On" position, the programming parameters are open to
change. JP1 is shipped in the "Off" position.
Programming Step by Step Guide
1. Remove the power source from the controller. Following the procedures in your
facility, lockout or tagout the power source.
2. Remove the cover from the control enclosure.
3. At the connection end of the drive, lift the black plastic dust cover up slightly and
slide it out of the back of the drive.
4. Locate the jumper labeled “JP1.”
5. Move the JP1 jumper from the “OFF” position to the “ON” position.
6. Slide the black plastic cover back into position.
7. Install the enclosure cover.
8. Remove any lockout/tagout devices in use as per procedures in place at your
facility, then connect the controller to the power source and power the unit up.
9. Press the Enter button until parameter selection mode is entered. When the drive is
in Parameter-Selection Mode, the far left of the display will be a “P.”
10. Use the Up and Down Arrow buttons to navigate to the desired parameter.
11. When the parameter number to be changed is displayed press the Enter button to
enter Value Mode. When in Value Mode, the two dots which form the colon
between digits two and three will alternately flash.
12. Use the Up and Down Arrow buttons to change the parameter’s displayed value.
13. Press the Enter button to return to Parameter-Selection Mode.
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14. Use the Up and Down Arrow buttons to go to the next parameter to be modified.
Repeat as required for any remaining parameters.
15. When all program modifications are completed, use the Up and Down Arrow
buttons to go to parameter “0” then press the Enter button to return to run mode.
16. Remove the power source from the controller. Following the procedures in your
facility, lockout or tagout the power source.
17. Remove the dust cover from the control enclosure.
18. At the connection end of the drive lift the black plastic cover up slightly then
slide it out of the back of the drive.
19. Locate the jumper labeled “JP1”.
20. Move the JP1 jumper from the “ON” position to the “OFF” position.
21. Slide the black plastic cover back into position.
22. Install the enclosure cover.
23. Remove any lockout/tagout devices in use as per procedures in place at your
facility, then connect the controller to the power source and power the unit up.
24. The drive is now ready to be used.
The required programming values for Extruder Tracking Control are located on
drawing number A0541236, one of three drawings that are included with the additive
feeder. If you do not have these drawings contact service to have them forwarded to
you.
Parameter # 37 requires the installer to program the correct pulses per revolution from
the extrusion machine.(See Chapter 5)
Extruder Tracking Control Application Notes
Input Pulse Signal Requirements
The drive uses a 5 volt DC square wave (TTL NPN type RPM signal) on its S2 input terminal
as a reference signal from the extruder. Please contact us for application assistance if your
extruder is not equipped with a method to provide this signal.
Minimum Input Pulse Rate
Extruder Tracking units are programmed to follow an extruder that provides eight pulses per
revolution. Additive Feeders used in extruder tracking systems REQUIRE end user
programming to match the master rate signal from the extruder’s screw if the signal
does NOT provide eight pulses per revolution. The value programmed into parameter P37
must be set to match the number of pulses per revolution that the extruder generates.
In addition, the drive must be provided a MINIMUM of 240 pulses per minute to provide
accurate results.
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Example 1: An extruder rotating at 30 RPM and providing 8 pulses per revolution generates
240 pulses per minute will provide excellent results.
Example 2: An extruder rotating at 15 RPM and providing 1 pulse per revolution generates
15 pulses per minute and will provide poor results.
Maximum Input Pulse Rate
As programmed, the drive is capable of accurately following an extruder’s rate signal of up to
50,000 pulses per minute. Extruders that provide rate signals above this frequency
REQUIRE end user programming to provide accurate results. The value programmed into
parameter P16 must be modified to a value that filters this pulse rate to an acceptable
frequency. Please refer to the parameter description section for additional information.
Example 1: An extruder rotating at 175 RPM and providing 8 pulses per revolution
generates 1,400 pulses per minute will provide excellent results.
Example 2: An extruder rotating at 250 RPM and providing 250 pulses per revolution
generates 62,500 pulses per minute and will provide poor results.
Minimum and Maximum Percent Setpoints
The drive rotates the additive feeder’s auger at a constant percentage of the extruder screw. If
the extruder screw is turning at 100 RPM and the setpoint is 50%, the additive feeder turns at
50 RPM. Increasing the extruder speed to 110 RPM will make the additive feeder rotate at
55 RPM. Decreasing the extruder speed to 90 RPM will make the additive feeder rotate at 45
RPM.
As programmed, the drive accepts percentage setpoints from 10% to 200% of the extruder’s
speed. The drive and motor’s acceptable operating speed range is 3 to 71 RPM.
Increasing the percent setpoint to a value that would cause the auger to rotate over 71 RPM
will NOT cause the feeder’s auger to rotate OVER 71 RPM.
Example 1: The extruder is rotating at 75 RPM, and the additive feeder percent setpoint is
85%. The additive feeder’s auger will rotate at 63.75 RPM.
Example 2: The same extruder’s speed setpoint is increased to 100 RPM without changing
the additive feeder percent setpoint of 85%. The additive feeder will rotate at its maximum
speed of 71 RPM, not at 85 RPM. If your application requires that additives be fed at a
higher rate than what71 RPM provides the simplest method is to increase the size of the
auger and sleeve your additive feeder is equipped with. Please refer to the parts section for a
complete listing of available sizes.
The minimum and maximum percent setpoints may be custom programmed to more precisely
reflect the range of speeds in use at your facility. Please refer to the parameter description
section for additional information.
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Chapter 5: Program Parameter Descriptions
5-1 Defining Program Parameters
Parameter 0 – Exit to Running Mode
When parameter 0 is selected in Parameter-Selection Mode, the unit will return to Running
Mode and display the running value. This should be selected once changes to parameters are
completed.
Parameter 10 – Operating Mode
This parameter defines the operating mode for the entire unit. There are two basic modes of
operation, master and follower. In master modes, the unit controls the load using rate or time
units. In follower mode, the unit controls the load in percentage of master rate.
Mode 1 – Master, Rate Mode
In Rate Mode, the drive displays in user-defined rate units such as RPM, Gallons per
Hour, or Feet per Second.
Mode 3 – Follower Mode
In Follower Mode, the drive displays in percentage units, where 1000 equals 100.0
percent of the master rate. For example, if the display indicates 985, 98.5, or 9.85, the
drive will attempt to run at exactly 98.5% of the master rate. Display settings are
always entered ignoring the decimal point's position.
Parameter 13 – Decimal Point (DP) Position
This selects the format of the display with respect to the decimal point’s position. This
parameter does not affect the value entry for other parameters. For example, if the user
desires to display 10.00 at 300RPM, then parameter 30 would be set to 1000, parameter 31
would be set to 300, and parameter 13 would be set to 2.
Mode 0: Fixed XXXX
Mode 1: Fixed X.XXX
Mode 2: Fixed XX.XX
Mode 3: Fixed XXX.X
Mode 4: Fixed XXXX.
Parameter 14 – Keypad Mode
This parameter selects the operating mode of the front-panel push buttons. In some
applications, increasing or decreasing the scroll rate provides the user more controllability
when entering settings. Parameters 14 and 15 affect only the Up and Down buttons when the
user interface is in Running Mode.
Mode 1: Linear, Constant Rate
In linear mode, pressing and holding the Up or Down buttons will cause the display to
continuously change value in the requested direction until either the Display Minimum
or Display Maximum is reached. The displayed value will scroll at a constant rate which
is specified using parameter 15.
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Mode 2: Non-linear, Accelerating Rate
In non-linear mode, pressing and holding the Up or Down buttons will cause the display
to continuously change value in the requested direction until either the Display
Minimum or Display Maximum is reached. The displayed value will initially scroll at a
slow rate and increase in speed until the maximum scroll rate is achieved. The initial
scroll rate is specified using parameter 15.
Parameter 15 – Keypad Scroll Mode
This parameter sets the scroll speed for the front-panel push buttons. The function of this
parameter varies slightly depending on the Keypad Mode. See parameter 14 for more details.
Parameter 16 – S1 / S2 Input Edge & Prescaler Configuration
This parameter determines how the drive processes the S1 and S2 signal inputs. It specifies
which signal edge is used for measurements and the value of the internal frequency dividers
or prescalers. Modes with prescalers greater than 1 should only be used if the input pulse rate
on S1 or S2 exceeds the unit's maximum native pulse rate (see specifications for details);
otherwise, the control loop may become sluggish and unnecessarily inaccurate. Use the
following chart to configure this parameter. As an example, assume an application requires
input pulse rates on S1 of 120,000 pulses-per-minute and S2 of 35,000 pulses-per minute.
According to the electrical specifications, the unit can only accept 50,000 pulses per-minute
on each the S1 and S2 inputs. With this in mind, the S1 and S2 prescalers should be selected
as Falling / 4 and Rising / 1, respectively. In this case, parameter 16 would be set to 2.
Parameter 18 – Power-up Mode
This parameter defines the mode which determines the default Running Value when power is
initially applied to the drive.
Mode 1: Default to Zero
When in this mode, the unit will default to zero (display units).
Mode 2: Default to Power-Up Value
When in this mode, the unit will default to the Power-up Value, parameter 19.
Mode 3: Default to Previously Running Value
When in this mode, the unit will default to the previous running value before power was
removed. A previous running value must have been active for at least 3 seconds to
be recalled after power has been disconnected and reapplied.
Mode 11: Display Intensity
Set value between 0-31 to adjust display brightness (31=brightest).
Additive Feeders
Chapter 5: Program Parameter Descriptions
35 of 55
Parameter 19 – Power-up Value
When Power-up Mode is set to 2, this parameter will designate the default display value at
power-up in display units.
Parameter 20 – Display Minimum
This parameter defines the lower end of the display range. This is the value which limits how
low the user is able to scroll the displayed value in Running Mode. In Rate and Time modes,
this value is set in display units. In Follower Mode, this is set in percentage of the master
rate. For example, in Follower Mode, 1250 represents 125.0 percent of the master rate. This
value can be changed but the feeder may not run consistently (choppy operation) if the
number of pulses per minute from the extruder are insufficient.
Parameter 21 – Display Maximum
This parameter defines the upper end of the display range. This is the value which limits how
high the user is able to scroll the displayed value in Running Mode. In Rate and Time modes,
this value is set in display units. In Follower Mode, this is set in percentage of the master
rate. For example, in Follower Mode, 150 represents 15.0 percent of the master rate.
Parameter 23 – Acceleration Setting
This parameter determines how fast the drive will accelerate toward the displayed target
setting. This parameter is set in display units of change per second such as RPM, GPM, or
feet per second. In Follower Mode, this parameter is set in RPM units.
Parameter 24 – Deceleration Setting
This parameter determines how fast the drive will decelerate toward the displayed target
setting. This parameter is set in display units of change per second such as RPM, GPM, or
feet per second. In Follower Mode, this parameter is set in RPM units.
Parameter 26 – Proportional (P) Gain
The Proportional Gain is the first of two parameters which define the responsiveness of the
control with respect to how fast it responds to changing loads. Because the drive controls are
pulse-accumulation drives, the P Gain responds differently than the same parameter in a
standard velocity-form PID control. The higher the P Gain, the more aggressively the unit
will drive the load.
Parameter 27 – Integral (I) Gain
The Integral Gain is the second of two parameters which define the responsiveness of the
control with respect to how fast it responds to changing loads. The higher the I Gain, the
more aggressively the unit will drive the load. When using high PPR pickups or encoders, it
will be necessary to decrease the I Gain to prevent unwanted oscillation and instabilities.
Parameter 30 – Signal Input 1 (S1) Display Reference
This is the number to be displayed when at the user-specified motor Reference RPM. In Rate
Mode, this value represents rate units such as feet, ounces, or revolutions. In Time Mode,
this value represents the reference time measured in seconds or minutes. If the desired
display is HH:MM, then all values should be entered in minutes. If MM:SS is desired, then
all values should be entered in seconds. In Follower Mode, this value is the percentage of the
master rate in 0.1% units. For example, 1000 equates to 100%.
Additive Feeders
Chapter 5: Program Parameter Descriptions
36 of 55
Parameter 31 – Signal Input 1 (S1) Reference RPM
This is the reference RPM at which the Display Reference value should be displayed. In Rate
and Time Modes, this value represents the RPM of the encoder to which the Display
Reference corresponds. In Follower Modes, this value is not used.
Parameter 32 – Signal Input 1 (S1) Pulses per Revolution
This is the number of pulses per revolution for the signal input 1 (S1). The drive supports
pickups and encoders from 1 to 2048 pulses per revolution.
Parameter 33 – Signal Input 1 (S1) Deadband (Follower Mode Only)
When in Follower Mode, it is often desirable for the follower unit to continue to slowly
make-up the small pickup pulse differential between the master and follower's position. In
some applications, it is not necessary for the follower to continue to slowly seek the master's
exact pulse position when the master rate is at zero. In these cases, the Deadband parameter
can be set above zero to force the drive to stop driving the motor slowly and cause it to inhibit
until the master starts rotating again. At that point, the follower will automatically make-up
the pulse differential as it starts to rotate. The deadband is disabled by setting it to zero
seconds.
Parameter 35 – Signal Input 2 (S2) Input Configuration
This parameter determines the operating mode of signal input 2 (S2).
Mode 1: Disabled (Follower Mode)
The S2 input is inactive. This is the required setting for Follower Mode.
Mode 2: Emergency Stop When S2 High (Not Wired To Common)
When the S2 input is at an electrically high (+5V) state or allowed to float disconnected, the
drive will enter emergency-stop mode. While in this mode, the armature output will
immediately be turned off. Once the S2 input returns to an electrically low state or wired to
the unit's common, the output will become active.
Mode 3: Emergency Stop When S2 Low (Wired To Common)
When the S2 input is at an electrically low state or wired to the unit's common, the drive will
enter emergency-stop mode. While in this mode, the armature output will immediately be
turned off. Once the S2 input returns to an electrically high (+5V) state or allowed to float
disconnected, the output will become active.
Mode 4: Inhibit When S2 High (Not Wired To Common)
When the S2 input is at an electrically high (+5V) state or allowed to float disconnected, the
drive will enter inhibit mode. While inhibited, the armature output will decrease according to
the decel setting until zero output is reached. Once the S2 input returns to an electrically low
state or is wired to the unit's common, the output will start to accelerate toward the previous
running value.
Mode 5: Inhibit When S2 Low (Wired To Common)
When the S2 input is at an electrically low state or wired to the unit's common, the drive will
enter inhibit mode. While inhibited, the armature output will decrease according to the decel
setting until zero output is reached. Once the S2 input returns to an electrically high (+5V)
state or allowed to float disconnected, the output will start to accelerate toward the previous
running value.
Additive Feeders
Chapter 5: Program Parameter Descriptions
37 of 55
Parameter 36 – Signal Input 2 (S2) Setpoint
When the S2 configuration, parameter 35, is set to one of the jog modes, this parameter
defines the jog setpoint in display units. If the drive operating mode is set to Follower Mode,
then this parameter is set in RPM units. This allows a follower control to be jogged when the
master is stopped.
Parameter 37 – Signal Input 2 (S2) Pulses per Revolution
This is the number of pulses per revolution for the signal input 2 (S2). The drive supports
pickups and encoders from 1 to 2048 pulses per revolution.
Parameter 95 – Factory Default Command
When set to a value of 5, the unit will be reset to factory default settings. This can also be
achieved by applying power to the unit with both the Enter and Down buttons depressed. The
programming jumper must be in the "On" position for this method to function.
Parameter 98 – Save to User Default Area Command
When set to a value of 5, the unit will store all adjustable parameters to the user default area.
The user default area is intended to be a location where an end user can store settings specific
to their application. Using this, an end user can easily refresh their custom settings in the
field if an someone accidentally reconfigures the unit unsuccessfully. Another common use
for this area is testing and initial setup. The user can store known-good settings here and
easily experiment without the fear of losing the optimal configuration.
Parameter 99 – Restore from User Default Area Command
When set to a value of 1, the unit will restore the all adjustable parameters from the user
default area. See parameter 98 for additional information.
Additive Feeders
Chapter 5: Program Parameter Descriptions
38 of 55
Chapter 6: Maintenance
6-1 Preventative Maintenance Schedule
The checklist below contains a list of items which should be inspected and/or replaced to
keep your Additive Feeder operating at peak efficiency. Perform each inspection at the
regular intervals listed below.
System model #
Every week
Serial #
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
By
By
By
By
By
By
By
By
By
By
By
By
By
Inspect auger,
sleeve and hopper
throat. Clean if
dirty.
Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Lock out electrical
power and inspect
electrical wiring for
integrity.
Visually inspect the
operation of motor
and auger while it
is operating.
- Photocopy this page for your maintenance records -
Additive Feeders
Chapter 6: Maintenance
39 of 55
6-2 Preventative Maintenance
This section describes maintenance procedures which will increase the longevity and
efficiency of your additive feeder. Perform them at the regular intervals listed on the
checklist on the previous page.
Material Cleanout/Changeover
Caution!
Never put hands or tools in or near the auger assembly when power is
connected!
Do not wear gloves or loose clothing when working near the auger
assembly!
1. Remove all remaining additive from the supply hopper by opening the cleanout
hatch. The motor assembly must be disengaged to fully open the cleanout hatch.
2. Re-engage the motor assembly and run any remaining additive out of the feeder by
opening the calibration hatch and holding the three-position motor switch in the
MANUAL position.
3. Disengage the motor assembly and remove the auger. Release the insert by pulling
the auger insert release knob on the side of the material transfer tube assembly.
Slide the insert out through the motor end of the transport tube. Clean both the
auger and the insert.
4. Clean the interior of the supply hopper and any additive remaining in the
calibration or cleanout hatches.
Additive Feeders
Chapter 6: Maintenance
40 of 55
6-3 Corrective Maintenance
This section provides you with the information necessary to correct or repair any issues
which might appear during the normal operation of your additive feeder. Although we have
listed how to perform these procedures, it is recommended that you call the Service
Department to have any in-depth maintenance performed.
Auger Assembly Changeover
Our additive feeder auger assemblies may be removed and installed without tools. All auger
sizes are interchangeable.
Caution!
Disconnect and/or lock out electrical power before removing an auger
assembly or performing any service or maintenance.
Removing Auger Assembly
1. Empty the supply hopper by swinging open the cleanout hatch.
2. Disengage the motor assembly from the auger by removing the motor mount
linchpin and swinging out the motor.
3. Pull the auger out.
4. Swing open the calibration hatch.
5. Release the UHMW auger insert by pulling out the spring loaded plunger and
turning it a quarter turn.
6. Slide the auger insert out through the transport tube assembly.
7. Clean any remaining additive from inside the feeder.
Installing Auger Assembly
Make sure the insert and auger to be installed are a matching set.
1. Slide the UHMW insert into the material transport tube. Line up the insert’s
groove with the locking pin in the side of the transport tube. Be sure the locking
pin is retracted.
2. When the locking pin is aligned with the insert’s groove, release the locking pin.
The locking pin will ride in the groove as the insert is pushed into the transport
tube.
3. When the insert is in place, the locking pin will snap into a retaining slot in the
insert’s guide groove.
4. Insert the matching auger into the insert and line up the motor coupler with the pin
on the end of the auger.
5. Fasten the motor assembly into place by restoring the linchpin to its original
position.
6. Close and secure the calibration and cleanout hatches.
Additive Feeders
Chapter 6: Maintenance
41 of 55
Motor Brush Replacement
The two (2) motor brushes should be replaced when they are worn down to less than 1 inch in
length. Replacement brushes are “pre-worn” by the manufacturer and require no break-in
period.
Caution!
Disconnect power to the Additive Feeder before changing the motor
brushes.
1. Remove a brush cap screw near the back of the motor.
Caution!
The motor brushes are spring loaded. Use care to avoid eye injury when
removing the cap screw. Wear safety glasses when performing this
procedure.
2. Remove the brush. Make note of the direction of the tapered end of the brush face.
3. Insert the new brush with the tapered end facing the same way as the worn brush.
4. Secure the new brush with the cap screw.
5. Repeat the above steps for the other brush.
The motor is now ready for use.
Contact Service to identify the correct brushes for your additive feeder. Be sure to have the
serial number of the equipment to be services to expedite the parts request.
Additive Feeders
Chapter 6: Maintenance
42 of 55
Chapter 7: Troubleshooting
7-1 Introduction
The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal troubleshooting must be accomplished
with the power off, line fuses removed, and with the machine tagged as out of service.
The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
Problem
Possible cause
Corrective action
No power to the control.
Power switch is off.
Fuse is blown.
Plug in control.
Turn power on.
Replace fuse.
Clear.
Auger is jammed.
Loose control wiring.
Power switch has failed.
Motor switch has failed.
Feeder is wired incorrectly to
the processing machine.
Control relay has failed.
Motor control has failed.
Motor brushes are worn.
Controller is in the program
mode. Display reads PROG.
Optional timer set incorrectly.
Optional timer mode set
incorrectly.
Tighten.
Replace.
Replace.
Refer to the control enclosure
wiring diagram.
Replace.
Replace.
Replace.
Feeder will not run with switch
in AUTO or MANUAL position.
Reset DIP Switch 7.
Reset timer.
Set operation mode to H and
configuration to d.
Replace.
Optional timer has failed.
Additive Feeders
Chapter 7: Troubleshooting
43 of 55
Problem
Possible cause
Corrective action
Remove jumper and wire the
terminals to the processing
machine relay.
Field contact jumper (J1) has not
been removed. AUTO MODE.
Field contact to the processing
machine has failed.
Check wiring/check the relay on
the processor.
Motor switch has failed.
Field contact to process machine
missing or loose.
Replace.
Motor will not stop.
Correct.
Control relay has failed.
Motor control has failed.
Optional timer set incorrectly.
Optional timer has failed.
Signal from motor speed sensor
missing.
Replace.
Replace.
Reset.
Replace.
Secure the sensor connections.
Motor runs only at maximum
speed.
Motor control has failed.
Motor speed sensor has failed.
Motor speed sensor magnet
misaligned.
Replace.
Replace.
Adjust.
Intermittent signal from motor
speed sensor.
Secure the sensor connections.
Motor speed not constant.
Motor speed sensor has failed.
Motor control has failed.
Material flow problem.
Replace.
Replace.
Inspect for blockage, etc.
Additive is contaminated by
color from previous run.
Feeder was not cleaned
adequately prior to operation.
See Section 6-2 on Page 39 for
cleanout instructions.
Power not applied
Using a volt meter, verify that a
voltage is measured between the
L and N terminal block
positions.
Display is blank.
Display is dim.
Defective unit.
Contact technical service.
Check wiring/check the relay on
the processor.
Display intensity.
Additive Feeders
Chapter 7: Troubleshooting
44 of 55
AC line supplying power has
too much noise.
Review routing of power wires
in machine to minimize
electrical noise. Look for other
devices which share the same
circuit and may be producing
unacceptable levels of line
noise. In some applications,
such as welding equipment, a
careful regiment of applying an
AC line filter, re-routing wires,
dividing circuits, using shielded
cable, and properly grounding
devices will usually solve the
problem.
When power is applied, “LF-L”
OR “LF-H” is displayed.
AC line supplying power to unit The unit is designed to operate
has an abnormally high
frequency.
with AC lines from 48-62 Hertz
(cycles per second). This is
typically not a problem because
the international standards are
50 and 60 Hertz.
Other service problems or questions can be answered by contacting the Service
Department.
Additive Feeders
Chapter 7: Troubleshooting
45 of 55
Chapter 8: Appendix
8-1 Technical Specifications
Annex B Information
The following design information is provided for your reference:
1.
2.
3.
4.
5.
6.
7.
No modifications are allowed to this equipment that could alter the CE compliance
Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit)
Environment: Clean, dust-free and non-explosive
Radiation:
Vibration:
None
Minimal, i.e. machine mounting
Allowable voltage fluctuation:
+/- 10%
Allowable frequency fluctuation:
Continuous
+/- 1%
Intermittent
+/- 2%
8.
9.
Nominal supply voltage:
460/3/60 (Verify on serial number tag)
Earth ground type: TN (system has one point directly earthed through a protective conductor)
10. Power supply should include a ground connection.
11. Over-current protection is supplied in the additive feeder, but additional protection should be
supplied by the user.
12. The door-mounted disconnect serves as the electrical disconnect device.
13. Additive feeder is not equipped with local lighting.
14. Functional identification
15. Additive Feeder is equipped with a CE mark
16. Additive Feeder is supplied with an operating manual in the language of the destination
country.
17. Cable support may be required for power cord, depending on final installation.
18. No one is required to be in the interior of the electrical enclosure during the normal operation
of the unit. Only skilled electricians should be inside the enclosure for maintenance.
19. Doors can be opened with a screwdriver, but no keys are required.
20. Two-hand control is not required or provided.
21. All additive feeders should be moved around and set in a place with a lift truck or equivalent.
22. There are no frequent repetitive cycles that require manual control⎯repetitive functions are
automatic while the additive feeder is operating.
23. An inspection report detailing the functional test is included with the additive feeder.
24. The machine is not equipped with cableless controls.
25. Color-coded (harmonized) power cord is sufficient for proper installation.
Additive Feeders
Chapter 8: Appendix
46 of 55
8-2 Drawings and Diagrams
Figure 3: Additive Feeder Specifications and Overall Dimensions
CONTROLS
MOUNTING FLANGE
I
I
SET POINT
4"
7"
SET POINT
91
2
9
"
1
"
2
POWER
MOTOR
ON
MOTOR ON
AUTO
OFF
POWER
MOTOR
OFF
MAN
ON
MOTOR ON
AUTO
OFF
OFF
MAN
4"
7"
61
4
"
61
"
4
STANDARD
STANDARD
WITH OPTIONS
27 3
"
4
12"
183
4
"
6"
1
"
4
31
Additive Feeder
Type
Hopper capacity
Electrical supply
Amp
draw
Shipping weight
1 Component
2 Component
1.0 Cu. Ft.
(2) 1.0 Cu. Ft.
115-1-60
115-1-60
1.3
2.5
50 lbs.
90 lbs.
Additive Feeders
Chapter 8: Appendix
47 of 55
Figure 4: Typical Additive Feeder Controllers
SET POINT
SET POINT
POWER
MOTOR
ON
MOTOR ON
POWER
MOTOR
OFF
ON
MOTOR ON
AUTO
OFF
OFF
MAN
Additive Feeders
Chapter 8: Appendix
48 of 55
8-3 Spare Parts List
Figure 5: Exploded Assembly Drawing
Figure 6: Parts List
Detail # Part number
Part/assembly description
Supply Hopper, 1.0 Cubic Foot
Supply Hopper, 2.0 Cubic Foot
1
1
A0541207
A0541208
A0541225
A0541226
A0541227
A0541286
A0541285
A0101190
A0541206
W0012471
2
2
2
3
Hopper Cover, Manual Fill
Hopper Cover with Cutout for .1 Cubic Foot Hopper Loader
Hopper Cover with Cutout for .25 Cubic Foot Hopper Loader
Magnetic Stripping for Supply Hopper Cover
Screw, ¼-20 x ½", HHC, Grade 5
Lock Washer, ¼"
4
5
6
7
Supply Hopper Sight Glass
Blind Rivet, 3/16"
8
W00052210 Plunger Pin, Retractable
9
A0541201
A0541202
A0541208
A0541205
A0069242
Material Transfer Tube
10
10
11
12
13
14
15
16
17
18
Main Throat, Standard, 6"
Main Throat, Optional Expanded, 8"
Main Throat Sight Glass
Flat Washer, 5/16
W00001948 Screw, 3/8-16 x ½"
A0069203
A0069458
A0541216
A0541215
A0540904
Lock Washer, 3/8"
Screw, 3/8-16 x 3/4"
Calibration Sample Port Plate
Clean Out Port Plate
Screw, 10-32 x ½"
Additive Feeders
Chapter 8: Appendix
49 of 55
Detail # Part number
Part/assembly description
19
20
21
22
23
24
25
25
25
25
25
25
26
26
26
26
Assy.
Assy.
Assy.
Assy.
Assy.
Assy.
27
W00052550 Knob, Knurled
A0069218
A0069549
A0541279
A0069241
A0541277
A0541209
A0541210
A0541211
A0541212
A0541213
A0541214
A0541219
A0541220
A0541219
A0541292
A0541292
A0541293
A0541294
A0541295
A0541296
A0541297
Stop Nut, 5/16-18
Flat Washer, 3/8"
Screw, 5/16-18 x 4½"
Flat Washer, ¼"
Quick Release Pin
Feed Tube Insert, 1/2"
Feed Tube Insert, 3/4"
Feed Tube Insert, 1"
Feed Tube Insert, 1 1/4"
Feed Tube Insert, 1 1/2"
Feed Tube Insert, 1 3/4"
Auger, 1/2"
Auger, 3/4"
Auger, 1"
Auger, 1 1/4"
Auger Assembly, 1/2" *
Auger Assembly, 3/4" *
Auger Assembly, 1" *
Auger Assembly, 1 1/4" *
Auger Assembly, 1 1/2"
Auger Assembly, 1 3/4"
W00015504 Roll Pin
28
29
30
A0541284
A0541217
A0541283
O Ring
Thrust Bearing
Compression Spring
31
W00000947 Lock Washer, #10
32
A0103129
Terminal Ring for Retaining Cable
33
W00013647 Pin Retaining Cable
34
35
36
36
36
37
37
37
37
37
37
38
A0541229
A0541282
A0555661
A0541298
A0547487
A0541265
A0541266
A0541267
A0541268
A0541269
A0544795
A0541039
A0541262
A0539035
Motor Mount
Jaw Coupler
Motor Assy, 115 VAC, 1/10 H.P.
Motor Assembly, 115 VAC 1/20 H.P.
Motor Assembly, 115 VAC, Low RPM 1/20 H.P.
Control, 115 VAC
Control, 115 VAC, Timer/Cycle Counter
Control, 115 VAC, Timer/Elapsed Timer
Control, 115 VAC, Extruder Tracking
Control, 115 VAC, Extruder Tracking, Timer/Elapsed Timer
230 VAC/115 VAC Transformer Control Assembly
Strain Relief for Control Cable
39
Lock Nut for Strain Relief
Transition Flange, Feed Throat, 7" to 4" Square
* Auger assemblies include details 26, 27, 28, 29, 30, & 12. Order the appropriately-sized feed tube
insert (Detail 25) if needed.
Additive Feeders
Chapter 8: Appendix
50 of 55
Figure 7: One Component Control Enclosure Parts Identification
ADDITIVE FEEDER
20
OR
19
6
41
11
5
SET POINT
18
16
17
4
3
9
7
8
9
POWER
MOTOR
ON
MOTOR ON
(SEE DETAIL A)
OFF
10 OR 52
2
1
Whitlock
50
14
15
12 13
TO ENCLOSURE
ON MOTOR
FUSE HOLDER
115V
POWER
ADDITIVE FEEDER
32
SET POINT
A0541236
DETAIL A
LEFT SIDE VIEW
OR
35
36 30
31
34
230V OPTION
50
1
A0544795
ASSY,TRANSFORMER,CNTL,230:115
POWER
MOTOR
33
ON
MOTOR ON
AUTO
OFF
EXTRUDER TRACKING
OPTION
41
40
1
1
A0541610
A0541673
GRAPHIC, CONTROLLER, PERCENT
SENSOR, OPTICAL, PICKUP
OFF
MAN
(SEE NOTE #2)
R
Whitlock
36
35
34
33
32
31
30
1
1
1
1
1
1
1
A0541238
A0541276
W00014736
A0541234
A0541252
A0541261
A0541259
TIMER, SOCKET, 11 PIN
COUNTER, ELAPSE TIME, LCD
SW, TOGGLE, DPDT, 0N-OFF-ON
GRAPHIC, TMR/CNT
ENCLOSURE, 8 x 6 x 6, TMR/CNT
COUNTER, CYCLE, LCD, TOTALIZER
TIMER, LCD, PRESET
TIMER/CYCLE COUNTER OR
TIMER/ELAPSE TIME COUNTER
OPTION
(SEE DETAIL B)
DETAIL B
TIMER/CYCLE COUNTER OR
TIMER/ELAPSE TIME COUNTER
20
19
2
1
A0541613
A0541235
A0541258
A0541262
A0541039
A0536541
W00012591
A0541611
A0803495
A0541233
A0536646
W00014276
A0541257
W00002540
A0541244
W00020484
A0534272
A0503765
A0541253
A0541251
SCRW,ROUND HD,6-32,1/2" LG,BLK
GRAPHIC, CONTROLLER
CABLE, 6 COND, SHIELD
NUT, LOCK, STRIAN RELIEF, 3/4"
STRAIN RELIEF, 3/4"
STRAIN RELIEF, PIGTAIL
CORD, SET, W/PLUG, 9', 115V ONLY
FUSE, 250V, MDL, 3/4 AMP
FUSE, HOLDER
18 10ft
17
16
15
14
13
12
11
10
9
8
7
6
5
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
GRAPHIC, STANDARD
LIGHT, GREEN, NEON
BOOT, RUBBER, TOGGLE SWITCH
SW, TOGGLE, DPDT, ON-OFF-MOM
SW, TOGGLE, SPST
CONTROLLER, SPEED, STANDARD
TERMINAL STRIP, 6 POSITION
SOCKET, RELAY
RELAY, DPDT
PANEL, SUB, 8 x 6
ENCLOSURE, 8 x 6 x 6, STANDARD
DESCRIPTION
NOTE:
1) OPTIONAL ITEMS ARE SHOWN WITH A DASHED
BOX.
2) ITEM #40 (NOT SHOWN ON DRAWING) TO BE
FIELD INSTALLED.
4
3
2
1
ITEM QTY PART NUMBER
STANDARD BILL OF MATERIAL
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8-4 Returned Material Policy
Credit Returns
Prior to the return of any material authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
8-5 Safety Tag Information
Additive Feeder Safety Tags
Read Operation
and Installation
Manual
Shear Hazard
Rotating Auger
High Voltage
Earth Ground
Inside Enclosure
PE Protected Earth
Ground
Lifting Point
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8-6 Additive Feeder Identification (Serial Number) Tag
(Located on back of Additive Feeder)
COMPANY LOGO
Additive Feeder
Serial # XXXXXXX
Model No. AF-XXX
Volt
Hz
Ph
AMP.
NEMA
Motor
Control Circuit Volt
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8-7 Technical Assistance
Parts Department
[
]
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call 262 641-8610, Fax [262] 641-8653
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
[
]
[
]
Call toll-free 8am–5pm CST 800 423-3183 or call 262 641-8610
[
]
Emergencies after 5pm CST, call 847 439-5655
We have a qualified service department ready to help. Service contracts are available for most of our
Sales Department
[262]
Call
641-8610 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
[262]
Call
641-8610 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or non-
union installations.
Sterling, Inc.
2900 S. 160th Street
New Berlin, WI 53151
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Worksheet for Charting Feed Rates
Material ________________________________
Auger size _______________________________
Feed rate unit of measure _________________
Trial #1 rpm _____________ Feed rate _______________
Trial #2 rpm _____________ Feed rate _______________
80
70
60
Auger 50
RPM
40
setting
30
20
10
0
____ ____ ____ ____ ____ ____ ____ ____
0
Observed feed rates (lbs./hr., oz./min., etc.)
- Photocopy this page for your records -
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