Additive Feeders
Contents
1. DETAIL B TIMER CYCLE COUNTER OR TIMER ELAPSE TIME COUNTER Additive Feeders ay 5 17 7 3 14 AI 18 n 21 16 CDM SEE DETAIL A lt A 7 10 o i C N p 45 4 P TO ENCLOSURE 12X13 PROX SWITCH ON MOTOR ITEM 22 FUSE HOLDER 115V 554 POWER N 0541237 DETAIL A LEFT SIDE VIEW 230VOPTION 50 1 A0544795 ASSEMBLY TRANSFORMER CNTL 230 115 EXTRUDER TRACKING 4 2 A0541610 GRAPHIC CONTROLLER PERCENT OPTION 40 2 20541673 SENSOR OPTICAL PICKUP SEE 2 34 38 1 A0505418 RELAY SOCKET a7 1 A0505417 RELAY 4PDT 25 M 36 1 A0541238 TIMER SOCKET 11 PIN 30 OR 36 35 2 A0541276 COUNTER ELAPSE TIME LCD TIMERICYCLE COUNTEROR 94 1 W00014736 SW TOGGLE ON OFF ON TIMERIELAPSE TIME COUNTER 33 1 A0541264 GRAPHIC TMRICNT OPTION 32 1 A0541255 ENCLOSURE 10 x 8 x 6 TMRICNT SEE DETAILB 154779 A0541261 COUNTER CYCLE LCD TOTALIZER 30 1 A0541259 TIMER LCD PRESET 2 1 A0536225 SW PROX NO CAP 18MM CAO010VCSN 22 1 0536549 STRF HEYCO 18 2 1150 20 4 A0541613 SCRW ROUND HD 6 32 1 2 LG BLK 19 2 0541235 GRAPHIC CONTROLLER 18 10ft 0541258 CABLE 6 COND SHIELD 1 A0541262 NUT LOCK STRAIN RELIEF 3 4 16 1 A0541039 STRAIN RELIEF 3 4 15 1 0536541 STRAIN RELIEF PIGTAIL 4 1 W000125912. 2 2 2 4 1 41 1 21 14 1 nnns 31 Additive Feeders iii CHAPTER 5 MAINTENANCE enm 32 5 1 Preventative Maintenance 5 1 32 5 2 Preventative 33 Material Cleanout ChangeoOver iai iiis eie kai ka nena RARE e ER vannene 33 5 3 Corrective Maintenance 34 Auger Assembly Changeover ee 34 Motor Brush Replacement sisse nnne nnn 35 CHAPTER 6 TROUBLESHOOTING 36 6 1 IN POGUCHOM EROR 36 CHAPTER 7 APPENDIX 2 2 38 EEE EEE RE TNT P 38 Warranty SPE CINCAUONS M 38 Warranty Restrictions DM I wn 38 Warranty Liabilities Mm 39 Customer nennen 39 7 2 Optional ener 39 7 3 Technical 41 Annex 9 0009 41 7 4 Drawings and DLAC AIS RR mmm 42 15 opare Parts Liste av 44 7 6 Returned Material Policy 48 Credit 48 Warranty Returns
3. Safety Symbols Used this 7 1 2 Warnings and PIecaullDnisz c pase tare ei e e vi 1522 JRESOOMSIDINNY vico Eee vii General Responsibility e i o rode oa Seed des docu ow nee Operator Responsibility eese Viii Maintenance Responsibility oot eri ie a be ee Ix Reporting a Safety Defect nennen nnn nnn nnns ix CHAPTER 2 FUNCTIONAL DESCRIPTION 10 2 1 Models Covered in This 10 2 2 General 10 2 3 Standard Features rrrrrrrrrrrrrrrrrrrrrrrrrrrnnrrnnrrnnrnnnrnnnrrnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnsnnne 10 d ue s ote 10 Electrical 15 P t t e tre rte 11 Controller Features or re P T vin d AERE AR RR Ra e 11 2 4 OPUONS EE 11 2297 INCCCSSONES sc 12 2 6 Safety Devices and lnterlockS caren diet ox sc gene tsar alee pus OU od tied recent 13 CHAPTER 3 1 1 15 3 1 Uncrating the 15 3 2 Rigging and Placing the Additive 15 3 3 Electrical Connections cus t eee e E erbe Em s
4. 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 e Scale e Sample container e Timer stopwatch watch clock w second hand Procedure 1 Close cleanout and calibration hatches Fill the additive supply hopper Weigh the empty sample container Set the controller to a desired RPM 2 3 4 Swing open the calibration hatch near the main throat 5 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 Note When the additive feeder is first powered up the motor control needs to warm up for a few seconds by running the motor until it stabilizes Subsequent operation will be instantaneous 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
5. To set up an additive feeder for cyclical processing you need to know shot size recovery time and the letdown ratio Cyclical Processing Equation Example Shot Size oz OZ Recovery time sec x Letdown ratio or 96 x sec Feed Rate Shot size 8 ounces Recovery time 5 seconds Letdown ratio 20 1 8 7 5 sec X 1 20 0 08 Desired feed rate To convert to Ibs hr 0 08 oz sec x 225 18 Ibs 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 Example Total throughput Ibs hr x percentage of additive Feed rate Total throughput 100 pounds per hour Percentage of additive 2 100 Ibs hr x 0 02 2 Ibs hr feed rate Additive Feeders Chapter 3 Installation 17 of 50 Figure 1 Conversion Chart Figure 2 Rate Chart Multiply Ounces per Second 225 To obtain Pounds per Hour Grams 0 035 Ounces Ounces 0 0625 Pounds Seconds 0 00028 Hours 110 100 110 Ib hr 90 80 70 60 50 40 55 Ib hr 30 20 25 Ib hr 10 7 Ib hr 1 2 Ib hr 1 1 2 Ib hr 4 Ib hr 7 Additive Feeders 1 2 auger 3 4 auger Chapter 3 Installation 1 auger 1 1 4 auger 18 of 50
6. DANGER indicates 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 Chapter 1 Safety v of 50 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 A RA RAR NN 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 t
7. NUT LOCK STRIAN RELIEF 3 4 16 1 A0541039 STRAIN RELIEF 3 4 15 4 30536541 STRAIN RELIEF PIGTAIL 14 1 W00012591 CORD SET WIPLUG 9 115V ONLY 13 1 AD541611 FUSE 250V MDL 3 4 AMP 12 1 0803495 FUSE HOLDER 1 1 A0541233 GRAPHIC STANDARD 10 4 0536646 LIGHT GREEN NEON NOTE 9 2 W00014276 BOOT RUBBER TOGGLE SWITCH 1 OPTIONAL ITEMS ARE SHOWN WITH A DASHED 811 0541257 SW TOGGLE ON OFF MOM BOX 711 W00002540 SW TOGGLE SPST 2 ITEM 40 NOT SHOWN ON DRAWING TO BE 1 10541244 CONTROLLER SPEED STANDARD FIELD INSTALLED 5 1 W00020484 TERMINAL STRIP 6 POSITION 1 A0534272 SOCKET RELAY 311 30503765 RELAY DPDT 2 1 A0541253 PANEL SUB 8 x 6 1 4 A0541251 ENCLOSURE 8 x 6 x 6 STANDARD QTY PART NUMBER DESGRIPTION STANDARD BILL OF MATERIAL Additive Feeders Chapter 7 Appendix 46 of 50 Figure 11 Two Component Control Enclosure Parts Identification 20 41 OR 19 10 33 3 35 OR 31 SET POINT 1 HIGH LEVEL SET POINT SET POINT 1 SET POINT 2 Low LEVEL SET POINT SET POINT 2 MOTOR 7 MOTOR ON auro gt N OFF SET POINT HIGH LEVEL SET POINT se pont SET POINT 1 Q LOW LEVEL MOTOR ON SET POINT SETPOINT 2 SET POINT 1 SETPOINT 2
8. 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 20 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 of Pulses per Revolution of the Feeder Screw Ifnot counted directly from screw multiply by a fudge factor to get the pulses per extruder screw rpm Factory set at 50 4 PPR x 25 2 gear ratio 4 Program the control to the new constant as described in the next section Field Control Programming 5 Change DIP switch 5 to ON Additive Feeders Chapter 4 Operation 26 of 50 6 Determine the desired additive feeder setpoint of extruder master screw RPM To determine this you must know Extruder Tracking Equation 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 Set Point rpm of feeder rpm of extruder x 100 Feeder auger rpm needed for 35 Ibs hr 44 rpm as the calibration procedure has Assuming
9. authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty No person agent manufacturer distributor dealer installer or company 15 authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser 7 2 Optional Components The following is a list of options which your Additive Feeder may have been equipped with Special Voltage e 230 1 50 VAC Timer Counter Control Designed for use with cycled processes like injection molding e Cycle timer can be set to limit additive feede
10. eee una 48 7 7 Safety Tag Information ETE 48 Additive Feeder named eee 48 7 8 Additive Feeder Identification Serial Number 49 7 9 Technical 49 Parts Department RR 49 Service 49 Sales 49 49 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
11. flip DIP switch 4 to OFF 5 The display should read PROG the decimal point if any is also displayed Viewing or Changing the Constant 1 Calculate the constant for your application using the formula listed on the previous page 2 Make sure you are in Programming Mode then flip switch 1 PROGRAM CONSTANT to ON 3 The current value for the constant FACTORY SETTING 30 should not be visible on the LED display 4 Usethe Up or Down buttons to adjust the constant value 5 When finished flip DIP switch 1 to OFF 6 The display should read PROG The display setting 1s set to the slowest speed when you exit the Programming Mode Programming for Follower Operation 1 Enter Programming Mode then turn switches 5 MASTER FOLLOWER SELECT and 1 PROGRAM CONSTANT to ON 2 Setconstant to CONSTANT 1000 x PULSES PER REVOLUTION OF MASTER PULSES PER REVOLUTION OF FOLLOWER 30 0 3 Turn OFF switches 1 and 7 4 Turn OFF AC power then reapply AC power The control is now set for follower operation Additive Feeders Chapter 4 Operation 29 of 50 Viewing or Changing the Program Minimum Setting l 3 4 5 Enter the programming mode then flip DIP switch 2 Program Minimum Setting to ON The current value for the lower limit FACTORY SETTING 0 will appear in the LED display Use the Up or Down buttons to change the lower limit as desired When finished flip DIP switch 2 to OFF The display sho
12. 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
13. 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 A Is the supply system if installed ready for operation Starting Up the Additive Feeder 1 Turn the power switch ON 2 Setthe 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 correcly it should begin operation at the desired RPM when the processing machine screw is in operation Shutting Down the Additive Feeder 4 Flip the motor switch to the OFF center position 5 Turn the power OFF For long term shutdown disconnect power and clean the additive feeder Additive Feeders Chapter 3 Installation 21 of 50 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 correcly it should begin operation at the desired RPM when the processing machine screw is in operation Controller Description and Operation Identif
14. 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 Additive Feeders Chapter 3 Installation 19 of 50 Examples This example shows how to extrapolate a desired feed rate of 3 Ibs hr based on the feed rates of 3 trial rpm settings Observed Feed Rates Sample 1 2 pounds per hour 0 20 rpm Sample 2 4 pounds per hour 0 40 rpm Sample 3 6 pounds per hour 0 60 rpm In this example a feed rate of 3 Ibs hr would be about 30 rpm Calculated feed rates Ibs hr the trial RPM s N wo A DN 0 0 10 20 30 40 50 60 70 Trial RPM settings Additive Feeders Chapter 3 Installation 20 of 50 3 5 Initial Start up Pre Startup Checks M Are all the electrical connections correct
15. 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 e NEVER try to pull material out of the feeder with your hands while it is running Before you start the feeder check the
16. 70 60 Auger 50 RPM 40 setting 30 20 10 0 Observed feed rates Ibs hr oz min etc Photocopy this page for your records Additive Feeders Chapter 7 Appendix 50 of 50
17. Additive Feeders Part Number 40541249 Bulletin Number WH6 605 2 Effective 12 12 12 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 O Copyright 2012 rights reserved Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department 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
18. CORD SET WIPLUG 9 115V ONLY 13 1 A0541611 FUSE 250V MDL 3 4 2 1 0803495 FUSE HOLDER 1 1 0541263 GRAPHIC DUAL SET POINT 10 3 0536646 LIGHT GREEN NEON 912 W00014276 RUBBER TOGGLE SWITCH 8 1 0541257 SW TOGGLE DPDT ON OFF MOM NOTE To W00002540 SW TOGGLE SPST 1 OPTIONAL ITEMS ARE SHOWN WITH A DASHED 612 0541244 CONTROLLER SPEED STANDARD BOX 5 1 W00020484 TERMINAL STRIP 6 POSITION 2 ITEM 40 NOT SHOWN ON DRAWING TO BE 412 0534272 SOCKET RELAY FIELD INSTALLED 312 0503765 RELAY DPDT 2 1 A0541256 PANEL SUB 10x8 1 A0541254 ENCLOSURE 10 x 8 x 6 ITEM QTY PART NUMBER DESCRIPTION STANDARD BILL OF MATERIAL Chapter 7 Appendix 47 of 50 7 6 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 1596 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 w
19. GH LEVEL SET POINT SET POINT 1 SET POINT SET POINT 2 LOW LEVEL SET POINT 2 MOTOR ON Additive Feeders Chapter 7 A f 100 oOo 100 cum SET POINT 1 HIGH LEVEL SET POINT 2 LOW LEVEL MOTOR ON Appendix 43 of 50 7 5 Spare Parts List Figure 8 Exploded Assembly Drawing i RANA ANNAN Need bs Figure 9 Parts List Screw 20 x HHC Grade 5 Lock Washer 6 A0541206 _ Supply Hopper Sight Glass O 7 W0012471 Rivet 3 16 8 WO00052210 PlungerPin Retractable 9 A0541201 Material Transfer Tube Screw 10 32 x Additive Feeders Chapter 7 Appendix 44 of 50 Detail Part assembly description W00052550 Knob Knurled A0069218 Stop Nut 5 16 18 A0069549 Flat Washer 3 8 Screw 5 16 18 x 4 Flat Washer 0541212 Feed Tube insert 1 1 4 A0541292 Auger 1 1 4 Auger Assembly 3 4 Auger Assembly 1 1 2 Auger Assembly 1 3 4 Terminal Ring for Retaining Cable A0541269 Control 115 VAG Extruder Tracking Timer Elapsed Timer A0541262 Lock Nut for Strain Relief A0539035 Transition Flange Feed Throat 7 to 4 Square Auger assemblies include details 26 27 28 29 30 amp 12 Order the appropri
20. access 3 Clamp the main throat to the machine with locking pliers 4 Boltthe main throat to the machine and the machine hopper to the main throat with the appropriate bolts nuts and lockwashers 5 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 15 of 50 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 e 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 a
21. achine hoppers Additive Feeders Chapter 7 Appendix 40 of 50 7 3 Technical Specifications Annex B Information The following design information is provided for your reference l SQ 067 Luc quy em NG 14 15 16 17 18 19 20 2 22 23 24 25 26 21 Additive Feeders No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 0 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 460 3 60 Verify on serial number tag 11 12 13 Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the additive feeder but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect device Additive feeder is not equipped with local lighting Functional identification Additive Feeder is equipped with a CE mark Additive Feeder is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installati
22. ately sized feed tube insert Detail 25 if needed Additive Feeders Chapter 7 Appendix 45 of 50 Figure 10 One Component Control Enclosure Parts Identification lt N 20 19 OR 41 N SET POINT 18 17 J sYT 9 N 3 a 4 fet e SEE DETAIL art 5 10 OR 82 P 1 N V 50 zd KV ul 15 12 13 TO ENCLOSURE ON MOTOR FUSE HOLDER 15 S POWER 2 32 SET POINT A0541236 DETAIL A 36130 31 OR 35 LEFT SIDE VIEW 34 230v OPTION 5 1 0544795 ASSY TRANSFORMER CNTL 230 115 33 MOTOR ON EXTRUDER TRACKING 41 1 0541610 GRAPHIC CONTROLLER PERCENT OPTION 49 1 0541673 SENSOR OPTICAL PICKUP SEE NOTE 42 36 1 0541238 TIMER SOCKET 11 PIN 35 1 0541276 COUNTER ELAPSE TIME LCD m MEE COUNTER OR 34 1 W00014736 SW TOGGLE ON OFF ON OPTION 39 1 A0541234 GRAPHIC TMRICNT SEE 32 1 A0541252 ENCLOSURE 8 x 6 x 6 TMR GNT DETAIL B aja A0541261 COUNTER CYCLE LCD TOTALIZER TIMERICYCLE COUNTER OR 30 1 0541259 TIMER LCD PRESET TIMER ELAPSE TIME COUNTER 2 20541613 SCRW ROUND HD 6 32 1 2 LG BLK 19 1 A0541235 GRAPHIC CONTROLLER 18 fot 0541258 CABLE 6 COND SHIELD 7 1 A0541262
23. ation please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 i Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 Phone 48 22 390 9720 Fax 48 22 390 9724 Shipping Information Unpacking and Inspection You should inspect your additive feeder for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportat
24. e 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 Additive Feeders Chapter 2 Functional Description 13 of 50 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 1s 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 a
25. ecessary refer to the parts catalog section No power to the control Plug in control Power switch is off Replace fuse Feeder will not run with switch in AUTO or MANUAL position Additive Feeders Auger is jammed Clear Loose control wiring Tighten Power switch has failed Replace Motor switch has failed Replace Feeder is wired incorrectly to the processing machine Refer to the control enclosure wiring diagram Control relay has failed Replace Motor control has failed Replace Motor brushes are worn Replace Controller is in the program mode Display reads PROG Reset DIP Switch 7 Optional timer set incorrectly Reset timer Optional timer mode set incorrectly Set operation mode to H and configuration to d Optional timer has failed Chapter 6 Troubleshooting Replace 36 of 50 Problem Possible cause Corrective action Field contact jumper J1 has not KEENE Jugend s terminals to the processing been removed AUTO MODE machine relay Field contact to the processing Check wiring check the relay on machine has failed the processor Motor switch has failed Replace Field contact to process machine missing or loose Control relay has failed Motor control has failed Optional timer set incorrectly Optional timer has failed Replace Signal from motor speed sensor c Secure the sensor connect
26. following e Remove all tools from the feeder Be sure no objects tools nuts bolts clamps bars are laying in the hopper area e If your feeder has been inoperative or unattended check all settings before starting the unit e At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e 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 e unsafe operation or condition e unusual feeder action e leakage e improper maintenance e 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 e Clean the feeder and surrounding area DAILY and inspect the machine for loose missing or broken parts e 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 Maintenance Respons
27. his 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 EXTEREME 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
28. ibility 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 Ifthere 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 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 When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handli
29. ill be assigned for the equipment to be returned Reason for requesting the return must be given 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 7 7 Safety Tag Information Additive Feeder Safety Tags Read Operation Shear Hazard and Installation Rotating Auger Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground Additive Feeders Chapter 7 Appendix 48 of 50 7 8 Additive Feeder Identification Serial Number Tag Located on back of Additive Feeder Company Logo C XX X Series Additive Feeder Model Number XX X Max Blend Capacity 318 KG HR 220V Serial Number 060701R 1 Date of Manufacture 06 2004 4 5A Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply 4 14 bar 60 psi Auger Speed 16 RPM Feeder Mass 400 Ibs 180 KG Electrical Diagrams amp Street Address City State Zip Code Telephone Number 7 9 Technical Assistance Parts Department Call toll free 5 CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 The ACS Customer Service Group will provide your com
30. ion company Substantiate the claim by referring to the agent s report certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on it You should have Additive Feeder Bill of lading Packing list Operating and Installation packet A RA RA Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For shipments in the United States and Canada call 1 800 233 4819 for all other countries call our international desk at 630 475 7491 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Additive Feeders ii Table of Contents CHAPTER 1 SAFETY verona V 1 1 How to Use This
31. ions missing Motor runs only at maximum Motor control has failed Replace speed Motor speed sensor has failed Replace Motor will not stop Correct Motor speed sensor magnet Adjust misaligned Intermittent signal from motor Secure the sensor connections speed sensor Motor speed not constant Motor speed sensor has failed Motor control has failed Material flow problem Inspect for blockage etc Additive is contaminated by Feeder was not cleaned See Section 5 2 on Page 34 for color from previous run adequately prior to operation cleanout instructions Other service problems or questions can be answered by contacting the Service Department Additive Feeders Chapter 6 Troubleshooting 37 of 50 Chapter 7 Appendix 7 1 Warranty Unless otherwise specified this product includes a Standard ONE YEAR PARTS AND LABOR WARRANTY Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES GUARANTIEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANTY FOR PARTS The Company s obligation is li
32. ive Feeders Chapter 2 Functional Description 11 of 50 2 5 Dual Setpoint Control Used with multiple feeder installations where one feeder is feeding colored regrind and another is feeding straight color A low level monitor senses when the supply of colored regrind is depleted and alters the feed rate of the pure color feeder to maintain precise color quality control automatically Extruder Following Feature e Pulse adder board increases range of microprocessor control to 500 000 pulses per minute to accommodate a wide variety of TTL type extruder rpm sensor signals e Feature is enabled with DIP switch adjustment Expanded Supply Hopper e 2 0 cubic foot capacity Supply Hopper Covers Hopper mounting cutout for vacuum receivers e Hopper loader mounting cutout for hopper loaders Additional Auger Assemblies e Switch augers for changing process throughputs Mounting Adapters e Special main throat and flanges can eliminate transitions and accommodate different machine hoppers Accessories Low Level Alarm e Audible visual alert to allow supply hopper level to avoid feeding straight resin into the processing machine e Remote mount e Advisory or process interrput capability e Alarm silence acknowledge button Drawer Magnet e Removes tramp metal from the process stream Additive Feeders Chapter 2 Functional Description 12 of 50 2 6 Safety Devices and Interlocks This section includes information on safety devices and p
33. mited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Warranty Restrictions This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned immediately without any further use or handling Additive Feeders Chapter 7 Appendix 38 of 50 Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so the above limitation may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts The company neither assumes nor
34. n The locking pin will ride in the groove as the insert 1s 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 5 Maintenance 34 of 50 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 E procedure 2 Remove the brush Make note of the direction of the tapered end of the brush face 3 Insert the new brush See Figure 5 below for Brush Part Numbers with the tapered end facing the same way as the worn brush 4 Secure the new brush with the cap screw Repeat the above steps for the other brush The motor is now ready for use Figure 5 Replacement Motor Brush Part Numbers Par
35. ng 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 ix 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 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 General Description Our additive feeder is a highly accurate unit designed to feed one or
36. on 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 Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All additive feeders should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control Trepetitive functions are automatic while the additive feeder is operating An inspection report detailing the functional test is included with the additive feeder The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Chapter 7 Appendix 4 of 50 7 4 Drawings and Diagrams Figure 6 Additive Feeder Specifications and Overall Dimensions MOUNTING FLANGE CONTROLS i i 4 7 9 T r L 4 2 T 400640 is STANDARD STANDARD WITH OPTIONS 27 12 1 N lt x N M N BS v N 3s gt 187 s PS N i Additive Feeder Hopper capacity Electrical supply Amp Shipping weight Type draw 1 Component 3 0 Cu Ft 115 1 60 50 Ibs 2 Component 1 0 Cu Ft 115460 25 90 Additive Feeders Chapter 7 Appendix 42 of 50 Figure 7 Typical Additive Feeder Controllers 2 SET POINT 4 MOTOR ON SET POINT 1 HI
37. or control If the supply of regrind drops below the proximity switch the regrind feeder stops and the other feeder switches to the Set Point 42 motor control When the regrind level in the regrind feeder supply hopper rises above the proximity switch the regrind feeder starts automatically and control of the other feeder is restored to Set Point 1 Dual Rate Feeder with Two Motor Controls Set Point 1 Motor Control Top High Level The Set Point 41 motor control should be calibrated and set to the feed rate needed to achieve the desired additive letdown rate when feeding both regrind and additive See calibration section This is typically lower than the Set Point 2 control setpoint Set Point 2 Motor Control Bottom Low Level The Set Point 2 motor control should be calibrated and set to the feed rate needed to achieve the desired additive letdown rate without the addition of any regrind into the process stream See calibration section This setpoint is typically higher than the Setpoint 1 control s setpoint If the Regrind feeder s supply level is below the proximity switch a relay stops its operation and puts the Setpoint 1 control in command instead until the regrind in the Regrind feeder s hopper rises back above the proximity switch Note Connect the proximity switch to the field contact terminals of the regrind control to turn the feeder system off on low level Additive Feeders Chapter 4 Operation 25 of 50 E
38. ormation 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 e 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 Additive Feeders Chapter 4 Operation 24 of 50 Dual Setpoint Control Operation 2 Component Applications A dual setpoint control operation is offered on the dual auger hopper additive feeder Typically one feeder hopper is filled with additive and the other with a proximity switch is filled with regrind This option allows for the accurate addition of additive and provides a consistant addition of regrind into the process stream Regrind Feeder with Proximity Switch The regrind feeder feeds regrind into the process stream Calibrate it to deliver the desired letdown ratio when operating with the other Set Point 1 feeder mot
39. pany 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 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 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 Call 630 595 1060 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 Additive Feeders Chapter 7 Appendix 49 of 50 Worksheet for Charting Feed Rates Material Auger size Feed rate unit of measure Trial f1 rpm Feed rate Trial 2 rpm Feed rate 80
40. pproved 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 Additive Feeders Chapter 2 Functional Description 14 of 50 Chapter 3 Installation 3 1 Uncrating the Equipment Additive feeders are shipped mounted on a skid enclosed in a plastic wrapper and contained 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 Usea 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 4 Lower slowly 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 Unbolt the machine 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
41. r brushes Electrical Features Motor Assembly e Continuous service fractional horsepower DC motor e Hall Effect sensor transmits RPM to microprocessor control e 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 e Field programmable display permits viewing in rpm pounds per hour kilos per hour etc as well as high low limits e Automatic and manual calibration operation modes Options Options marked with 4 indicate options that can be factory installed or retrofitted in the field Special Voltage e 230 1 50 VAC Timer Counter Control Designed for use with cycled processes like injection molding e Cycle timer can be set to limit additive feeder cycle to avoid feeding straight color if a resin supply problem occurs in conjunction with a processing machine control relay failure e Batch counter provides inventory management information e Calibration feature allows precise repeatable sampling during setup Timer Elapsed Timer Control e Designed for use with continuous processes like extrusion e Elapsed timer provides inventory management information e Calibration feature allows precise repeatable sampling during setup Addit
42. r cycle to avoid feeding straight color if a resin supply problem occurs in conjunction with a processing machine control relay failure e Batch counter provides inventory management information e Calibration feature allows precise repeatable sampling during setup Timer Elapsed Timer Control e Designed for use with continuous processes like extrusion e Elapsed timer provides inventory management information e Calibration feature allows precise repeatable sampling during setup Additive Feeders Chapter 7 Appendix 39 of 50 Dual Setpoint Control Used with multiple feeder installations where one feeder is feeding colored regrind and another is feeding straight color A low level monitor senses when the supply of colored regrind is depleted and alters the feed rate of the pure color feeder to maintain precise color quality control automatically Extruder Following Feature e Pulse adder board increases range of microprocessor control to 500 000 pulses per minute to accommodate a wide variety of TTL type extruder rpm sensor signals e Feature is enabled with DIP switch adjustment Expanded Supply Hopper e 2 0 cubic foot capacity Supply Hopper Covers Hopper mounting cutout for vacuum receivers e Hopper loader mounting cutout for hopper loaders Additional Auger Assemblies e Switch augers for changing process throughputs Mounting Adapters e Special main throat and flanges can eliminate transitions and accommodate different m
43. re 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 The additive feeder will automatically operate while the screw is turning Please refer to the schematics enclosed in the information packet for the latest electrical drawings Additive Feeders Chapter 3 Installation 16 of 50 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 provide conversion and rate charts to assist you in your calculations For Cyclical Processing Injection Molding etc
44. rective 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 pluger 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 pi
45. rical power and inspect electrical wiring for integrity Visually inspect the operation of motor and auger while it is operatng Photocopy this page for your maintenance records Additive Feeders Chapter 5 Maintenance 32 of 50 5 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 SPI 034 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 5 Maintenance 33 of 50 Cor
46. rocedures 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 e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device 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 devic
47. service For immediate assistance please contact North Central and South America 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you 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 For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more inform
48. t Number Description A0541239 115 VAC controls motor plate marked 90 VDC 1 20 HP A053426 BS 115 VAC controls motor plate marked 90 VDC 1 10 HP Additive Feeders Chapter 5 Maintenance 35 of 50 Chapter 6 Troubleshooting 6 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 trouble shooting 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 n
49. tedt 16 3 4 Setup Fe eps e E Ld e POR Te lye 17 Determining the Desired Feed Rate aestate 17 Calibration nnne nnns nnn nnn nn nn 19 3552 eer e areae Er ER ee te ust E 21 gt 51 10 de eid P iuto deus 21 Starting Up the Additive Feeder itd 21 shutting Down the Additive Feeder eet 21 CHAPTER 4 OPERATION 22 4 1 dece dee e 22 4 2 Controller Description and Operation 22 Identifying Control Panel Indicator Lights and Switches on the Controller 22 Timer Counter Control Operation Injection Molding Applications 23 Timer Elapsed Timer Control Extrusion amp Blow Molding Applications 24 Dual Setpoint Control Operation 2 Component Applications 25 Exiruder Tracking ise teri obi o hela ie Ee een beg oodd 26 Extruder Tracking Installation and Setup 26 Field Control reiciendise de vente dere redekasse 28 Additive Feeder Control Factory Defaults seen 31 4 3 Shutting Down the Additive
50. this set point 44 rpm 50 rpm x 100 88 or 88 of the extruder screw speed Example Total extruder feedrate 500 pounds per hour Extruder screw rpm for 500 Ibs hr 50 rpm Additive letdown percentage 7 Additive feedrate 500 X 0 07 35 Ibs hr shown Additive Feeders Chapter 4 Operation 27 of 50 Equation C Example 1 Equation Field Control Programming The standard additive feeder controller has the ability to display feed rates in units other than the factory set auger RPM display With the proper programming the feeder can display pounds hour grams minute etc The non volatile memory retains the program if the power is interrupted Note The field programmer should have a basic understanding of programmable motor controls before attempting to reprogram the display Page 32 lists the factory default settings WARNING This procedure involves resetting a DIP switch within a live electrical enclosure Only persons with the proper knowledge of and respect for working on energized electrical devices should attempt this procedure Use extreme caution To program a custom feed rate display first calculate the new constant ONSTANT 1500 X DESIRED DISPLAY SETTING MOTOR RPM X PULSES PER REVOLUTION Desired Display Setting This is what you want to see on the display during operation For example if you are programming to display pounds hour and you want to feed ten pounds hour this number would be 10 Mo
51. tor RPM 25 2 X Auger RPM If calibration determines that a 40 rpm auger speed delivers 10 pounds per hour multiply 40 by the gearbox ratio 25 2 1 to calculate motor rpm for example 1 008 Pulses Per Revolution 2 The motor shaft magnet sensor pulses twice per motor revolution Calculating a constant to display pounds per hour If calibration Page 20 determines that for example a 40 rpm auger speed feeds 10 pounds per hour the following calculation will permit programming the display to read in pounds per hour The constant calculated has been rounded to the desired decimal place Constant 1500 x 10 25 2 x 40 x 2 7 44 Example 2 Equation How the factory pre set constant was calculated Constant 1500 25 2 x 2 30 0 Additive Feeders Chapter 4 Operation 28 of 50 Programming Mode The motor will stop when in Programming mode 1 Make sure DIP switches through 4 and 7 and 8 are OFF 2 Flip switch 7 to ON 3 The display should read PROG 4 Follow the instructions given below to view and or edit any of the variables Viewing or Changing Displayed Decimal Place Rate or Time Mode Select 1 Make sure you are in Programming Mode then flip DIP switch 4 RATE TME MODE PROGRAM DECIMAL PLACE ON 2 The current decimal point setting if any FACTORY SETTING 0 will be displayed 3 Usethe Up or Down buttons to change the decimal point as desired Use 0 for NO decimal point 4 When finished
52. tor is running in AUTO mode Procedure 1 Time the duration of feeder operation during a typical Injection molding machine shot cycle 2 Setthe timer to a slightly longer value 3 Start the additive feeder by flipping the motor switch to the AUTO position 4 Ifthe timer times out because of a process flow problem the feeder will automatically stop 5 Resetthe 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 e 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 Additive Feeders Chapter 4 Operation 23 of 50 Timer Elapsed Timer Control Extrusion amp 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 20 for specific calibration instructions 1 Setthe timer to the desired calibration period using the round timer keys see the timer inf
53. 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 Standard Features Mechanical Features Transport Tube e Stainless steel augers available in gt 4 1 1 1 4 and 1 1 2 sizes e Augers insert assemblies are interchangeable without tools UHMW polyethylene auger insert is durable and easily cleaned e Calibration hatch opens without tools e Cleanout hatch below the flood zone opens without tools and allows the supply hopper to dump completely e Lightweight aluminum casting Main Throat Low profile design adds only 6 inches to supply system headroom requirements e Accomodates one or two transport assemblies e Sturdy steel construction Supply Hopper e cubic foot capacity 45 pounds 45 Ib cubic foot e Design based dynamic static material flow characteristics Angled hopper geometry allows use with 60 machine supply hoppers e Easy fast and complete cleanout e Sight glasses give visual level indication e Manual fill cover standard Additive Feeders Chapter 2 Functional Description 10 of 50 Motor Assembly e Quick release swing away motor mount speeds auger motor changes and cleanout e Permanently lubricated e Replaceable moto
54. uld read PROG Viewing or Changing the Program Maximum Setting 1 4 25 Enter the programming mode then flip switch 34 PROGRAM MAXIMUM SETTING to ON The current value for the upper limit FACTORY SETTING 70 will appear in the LED display Use the Up or Down buttons to change the upper limit as desired When finished flip DIP switch 3 to OFF The display should read PROG Exiting Programming Mode and Returning to Run Mode l 23 3 4 Make sure DIP switches 4 TIME RATE MODE SELECT and 5 MASTER FOLLOWER MODE SELECT are in the desired positions factory Setting 4 1 5 OFF ON FOR OPTIONAL EXTRUDER TRACKER CONTROLS BEFORE entering the RUN mode DIP switch 7 OFF Make sure DIP switches 1 through 4 are OFF If satisfied with the programmed values flip DIP switch 7 to OFF Control should begin to operate normally using the values and modes selected Figure 3 DIP Switch Function Table Switch 1 Program Constant Switch 2 Program Minimum Setting Switch 3 Program Maximum Setting Switch 4 Decimal Select 0 4 Decimal Points Switch 5 Master Follower Select OFF Master ON Follower Switch 6 Do Not Use Set to OFF Switch 7 Program Run Select OFF Run ON Program Switch 8 Do Not Use Set to OFF Additive Feeders Chapter 4 Operation 30 of 50 Additive Feeder Control Factory Defaults WARNING This procedure involves resetting a DIP switch within a li
55. 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 warning and danger signs must be observed and obeyed actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater 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 18 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 e Breakdown of shop morale Costly damage to equipment e Downtime An effective safety program 18 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
56. ve electrical enclosure Only persons with the proper knowledge of and respect for working on energized electrical devices should attempt this procedure Use extreme caution Note Set the decimal point with DIP switch 4 first to avoid confusion when keying in the presets for example 300 and 30 0 Figure 4 Additive Feeder Control Factory Defaults DIP Variable Pre set Switch 1 Auger RPM Constant 30 0 Switch 2 Program Minimum 0 0 Switch 3 Program Maximum 70 0 Switch 4 Decimal Place 0 3 Switch 5 Master Follower Select Standard Control OFF Optional Extruder Tracking Control ON 4 3 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 Additive Feeders Chapter 4 Operation 31 of 50 Chapter 5 Maintenance 5 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 GE ERES VEIT LN URGE TI pp pp pp pp EE Ie p pom s dirty ge et OE EE tt Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Lock out elect
57. xtruder 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 1 to 999 9 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 e Inductive proximity sensors to sense gear teeth Magnetic pickups to sense affixed magnets e Optic sensors to sense affixed reflective tape Consult your sales representative for additional information 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 Connect the TTL signal acquired from the extruder control or from a sensor you have installed to the terminal strip
58. ying 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 e OFF stops the auger motor e 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 Additive Feeders Chapter 4 Operation 22 of 50 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 20 for specific calibration instructions Procedure 1 Setthe 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 mo
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