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Sterling AF-XXX Wheelchair User Manual

1. E Ke N Z 3 19 OR 41 E e PN J S 18 16 7 S A S 4 917 8 9 3 A 3 A dM 8 SEE DETAIL A ale h E Kall ACC V y ZO N C s 25 TOENCLOSURE ONNDTOR FUSE HOLDER nw E d POWER ED E eene e 2 ACbA1236 i DETAIL A 36 30 31 Om 35 LEFT SIDE MEW 3 zovornion 50 1 ABA ASSY TRANSFORINER CNL 230 115 E a EXTRUDERTRACKING 41 1 Soen GRAPHIC CONTROLLER PERCENT lt oe mii APE SENSOR OPTICAL PICKUP la Se TIER SOCKET 11 PIN c EO A276 COUNTER ELAPSE TIVE LCD IMER CYCLE COUNTER a 1 WXOMZ SW TOGGLE DPDT ONOFF ON TIMERELAPSE TIVE COUNTER 7 3 1 apen GRAPHC TMRCNT SEEDETALB 2 1 Es ENCLOSURE 8x6x6 TMRCNT DETAILB ES AADGl COUNTER CYCLE LCD TOTALZER TIVERICYCLE COUNTER OR 30 1 Me TIMER LCD PRESET ERR mer SCRWROUNDHD622 12 LGBLK 79 1 Ae GRAPHCCONIROLER SI _AQS41258_ CABLE GCOND SHELD STi Se NUT LOCK STRIANRELIEF 3 4 1 Sa STRAINRELIEF 34 B 1 Aen STRAINRELIEF PIGTAIL m 1 Wo CORD SET WPLUG 9 IVONY B 1 Anen _ FUSE 5V ML 3AANP 2 1 AHBE5 FUSE HOLDER Tl 1 An GRAPHIG STANDARD D 1 ABA LIGHT GREEN NEON NOTE 9 2 woe BOOT RUBBER TOGGLE SWITCH 1 OPTIONAL ITEMS ARE SHONN WITHA DASHED 8 1 AS SW TOGGLE DPDT ON OFF MOM BOX 7 1 weng SWTOGGE SPST 2 ITEM 40 NOT S
2. 11 2 1 Models Covered in This Manual 11 2 2 EN MRT TEE 11 2 3 Standard Kee 11 Mechanical FOSEUFeS EE 11 Electrical E 12 Controller POSU BS ust Ma ottiene eter peto decet sen e Re D sates 12 no wirds RE 12 CE MM ACCOSSONOS Tr KEE EE eege Ee 13 2 6 Safety Devices and Interlocks ete pee ete cttee nete egere toes ep leon s 13 CHAPTER 3 INSTALLATION ee eee 15 3 1 Uncrating the EE soot rct erit eire aec too pedetentim e tani tea 15 3 2 Rigging and Placing the Additive Feeder eeeesseeeessssss 15 3 9 Electrical CONNECTIONS TE 16 3 4 Setup dee imei eet Hh Pech st teme eT tke aE ar TERRE Ra Ei REIR 17 Determining the Desired Feed Fate sss 17 Calibration PrOGedure iere gite dedito EE L en 19 EN MEET WEE 21 Pre Starntup CROOKS 286 nasa MEC cst 21 Starting Up the Additive Feeder re e is Ati ete ee xke rat HE Reb 21 Shutting Down the Additive Feeder seen 21 CHAPTER A OPERATION eene nnn 22 4A En GD 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 22 Timer Elapsed Timer Control Extrusion amp Blow Molding Applications 23 4 3 Injection Mold
3. 2 Nominal supply voltage 460 3 60 Verify on serial number tag 9 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 Noone 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 Trepetitive functions are automatic while the additive feeder is operating 23 Aninspection report detailing the functional test is included with the additive feeder 24 The machine is not equipped with cableless controls 25 Color co
4. 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 Additive Feeders Chapter 4 Operation 32 of 55 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 param
5. Ounces Ounces 0 0625 Pounds Seconds 0 00028 Hours 110 Ib hr 55 Ib hr 25 lb hr 7 Ib hr 1 2 lb hr 1 1 2 lb hr 4 Diir 7 lb hr 1 2 auger 3 4 auger 1 auger 1 1 4 auger Chapter 3 Installation 18 of 55 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 2 Fillthe additive supply hopper 3 Weigh the empty sample container 4 Swing open the calibration hatch near the main throat 5 Setthe 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
6. 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 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 transportation company Substantiate the claim by referring to the agent s report A 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 a
7. Chapter 4 Operation 3 of 55 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 Atthe 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 2 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
8. 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 EC and Installation Manual Shear Hazard Rotating Auger High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground Additive Feeders Chapter 8 Appendix 52 of 55 8 6 Additive Feeder Identification Serial Number Tag Located on back of Additive Feeder Additive Feeders COMPANY LOGO Additive Feeder Model No AF XXX Serial XXXXXXX Volt Hz Ph Motor Control Circuit Volt Chapter 8 Appendix AMP 53 of 55 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 80
9. 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
10. 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 Atthe 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 Usethe Up and Down Arrow buttons to change the parameter s displayed value 13 Press the Enter button to return to Parameter Selection Mode Additive Feeders
11. 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 e Loss of a skilled operator temporarily or permanen
12. 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 Additive Feeders 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 Chapter 3 Installation 19 of 55 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 Ibs hr would be about 30 rpm 8 Calculated 7 feed rates 6 3 Ibs hr the 5 2 trial RPM 4 3 4 2 1 1 0 o 10 20 30 40 50 60 70 Trial RPM settings Additive Feeders Chapter 3 In
13. 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 Additive Feeders Chapter 4 Operation 27 of 55 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
14. 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 e Inductive proximity sensors to sense gear teeth Magnetic pickups to sense affixed magnets e 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 c
15. 0 423 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 products www acscustomerservice com Sales Department Call 262 641 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 Call 262 641 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 160 Street New Berlin WI 53151 WWW sterlco com Additive Feeders Chapter 8 Appendix 54 of 55 Worksheet for Charting Feed Rates Material Auger size Feed rate unit of measure Trial 1 rpm Feed rate Trial 2 rom Feed rate 80 70 60 Auger 50 RPM An setting 30 20 10 0 RE Observed feed rates Ibs hr oz min etc Photocopy this page for your records Additive Feeders Chapter 8 Appendix 55 of 55
16. Br de puses 40 6 3 Corrective Malnteriali6e noob Egger 41 Auger Assembly ChangeoV r retrait ti hei napa HERR P une be ERR TH Ron uebuh 41 Motor Br ush Heplacemoeht EEN 42 CHAPTER 7 TROUBLESHOOTING m 43 ELM cioe ors rm 43 CHAPTER 8 APPENDIX 1 ceno ecc nne hakanu niasa 46 8 1 Technical Specifications eeh Steet ae 46 Annex B InformalOM EE 46 8 2 Drawings and DiagramS EE 47 8 3 Spate Pans EISL ccc E 49 8 4 Returned Material Policy s c te to bu Ii teg cet ect t bei erus 52 Credit Return ME EE 52 Warranty Heltuffis e oov Gone Eege 52 8 5 Safety Tag Information ette cepe tatus aT bc bd niae 52 Additive Feeder Safety TagS oe epp scb ne ap epus erreur aerae yen Regen oe eE 52 8 6 Additive Feeder Identification Serial Number Tag 53 e Rn lie Ee 54 Parts Dopamenl EE 54 Service Department t e t EM t qe qu dad E M eue 54 Eeer 54 Contract DE DANINGIIE sca sacs As sat eoo ste rendue ph ais oaa EE 54 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 model
17. HOAN ON DRAWING TO BE 6 1 apum CONTROLLER SPEED STANDARD FIELDINSTALLED 5 1 Wm TERMINAL STRIP GPOSITION 4 1 AE3U72 SOCKET RELAY 3 1 ACERS RELAY DPDT 2 1 A PANEL SUB 8x6 1 1 Ans ENCLOSURE 8x6x6 STANDARD DEM QTY PARTNUMBER DESCRIPTION STANDARD BILL OF MATERIAL Additive Feeders Chapter 8 Appendix 51 of 55 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
18. 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 amp 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 t
19. O 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 Additive Feeder Safety Tags Shear Hazard Rotating Auger Read Operation and Installation Manual High Voltage Earth Ground Inside Enclosure Protected Earth Lifting Point Ground 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 equ
20. 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 responsive
21. 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 kno
22. bove 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 Additive Feeders Chapter 2 Functional Description 14 of 55 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 wood supports Cut the steel banding 2 Usea pry bar to remove the blocks securing the unit to the skid 3 Liftunit 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 h
23. cent 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 Additive Feeders Chapter 4 Operation 33 of 55 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 perc
24. cess 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 9c 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 Ibs 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 Ibs hr x percentage of additive Feed rate Example Total throughput 100 pounds per hour Percentage of additive 2 100 Ibs hr x 0 02 2 lbs hr feed rate Additive Feeders Chapter 3 Installation 17 of 55 Figure 1 Conversion Chart Figure 2 Rate Chart Additive Feeders 110 100 90 80 70 60 50 40 30 20 10 0 Multiply Ounces per Second 225 To obtain Pounds per Hour Grams 0 035
25. ded 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 MOUNTING FLANGE Additive Feeder Type CONTROLS ew ew STANDARD STANDARD WITH OPTIONS 2 1 0 Cu Ft Additive Feeders Chapter 8 Appendix 47 of 55 Figure 4 Typical Additive Feeder Controllers SET POINT POWER MOTOR ON MOTOR ON AUTO NA Additive Feeders Chapter 8 Appendix 48 of 55 8 3 Spare Parts List Figure 5 Exploded Assembly Drawing Figure 6 Parts List Screw 14 20 x 1 2 HHC Grade 5 Lock Washer 1 4 6 A0541206 SuppyHopperSightGlass Z O 8 WO0052210 Plunger Pin Retractable 9 A0541201 Material TransferTube Screw 3 8 16 x 1 2 Screw 10 32 x 1 2 Additive Feeders Chapter 8 Appendix 49 of 55 Flat Washer 1 Auger Assembly 1 1 4 Auger Assembly 1 3 4 A0539035 Transition Flange Feed Throat 7 to 4 Square Auger assemblies include details 26 27 28 29 30 amp 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
26. displayed value Press the Enter button to return to Parameter Selection Mode Use the Up and Down Arrow buttons to go to the next parameter to be modified Repeat as required for any remaining parameters 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 Remove the power source from the controller Following the procedures in your facility lockout or tagout the power source Remove the dust cover from the control enclosure At the connection end of the drive lift the black plastic cover up slightly then slide it out of the back of the drive Locate the jumper labeled JP1 Move the JP1 jumper from the ON position to the OFF position Slide the black plastic cover back into position Install the enclosure cover 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 Additive Feeders Chapter 4 Operation 26 of 55 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 ra
27. e 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 Additive Feeders Chapter 4 Operation 24 of 55 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 Selecti
28. enance 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 Pull the auger out 4 Swing open the calibration hatch 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 the
29. entage 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 Additive Feeders Chapter 5 Program Parameter Descriptions 34 of 55
30. er 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 Additive Feeders Chapter 3 Installation 16 of 55 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 pro
31. er 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 Additive Feeders Chapter 4 Operation 30 of 55 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
32. er set incorrectly Reset timer Optional timer mode set incorrectly Set operation mode to H and configuration to d Optional timer has failed Chapter 7 Troubleshooting Replace 43 of 55 Problem Possible cause Corrective action Field contact jumper J1 has not Remove JUnperand ne ER 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 has failed Replace missing speed Motor speed sensor has failed Replace Motor will not stop Correct Motor speed sensor magnet Adjust misaligned Intermittent signal from motor 7 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 6 2 on Page 39 for color from previous run adequately prior to operation cleanout instructions Power not applied Using a volt meter verify that a voltage is measured between the L and N terminal block Display is blank positions E unit pue technical service Display is dim Display intensity eer inem the relay on Additive Feeders Chapter 7 Troubl
33. eshooting 44 of 55 AC line supplying power has too much noise When power is applied LF L OR LF H is displayed AC line supplying power to unit has an abnormally high frequency 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 The unit is designed to operate 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 l No modifications are allowed to this equipment that could alter the CE compliance 2 Ambient temperature 0 degrees Celsius Maximum 104 degrees Fahrenheit 3 Environment Clean dust free and non explosive 4 Radiation None 5 Vibration Minimal i e machine mounting 6 Allowable voltage fluctuation 10 7 Allowable frequency fluctuation Continuous 1 Intermittent
34. esign adds only 6 inches to supply system headroom requirements e Accommodates one or two additive feeders e Sturdy steel construction with sight glasses to visually confirm proper operation Supply Hopper e 1 or 2 cubic foot capacity Design based on dynamic static material flow characteristics e 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 11 of 55 2 4 Motor Assembly Quick release swing away motor mount speeds auger motor changes and cleanout e Permanently lubricated e Replaceable motor 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 e 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 Special Voltage e 230 1 60 VAC Timer Counter Control e Designed for use w
35. eter 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 5096 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 per
36. his 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 Selection Chart S1 Input Edge and Prescaler Rising 1 ES 11 CUTS 14 Falling 16 2 Input Edge and Prescaler Falling 4 Falling 16 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
37. ing Applications 5 aoi eiat escola eerte rat tenete 24 Steps that must be completed before the additive feeder will perform properly 24 Injection Molano Ss rote c oc te rtr or bce eens AA savers desea tuer dedius tuus 24 Control Relay Connection o c igi Ra bes yp e Do ooi ek 24 Field Control e ee ee EE 24 Additive Feeders lii Resetting the Unit to Un Programmed State sss 25 JP1 Program Enable JUImpOt ege EE Ee eg 25 Programming Step by Step QUuiU6 arta rer Fere lt earn d erano ades 25 Injection Mode Application Notes eee eee 27 4 4 Extrusion AppliCallOris ero oro Go oerte Ee ENER 28 Steps that must be completed before the additive feeder will perform properly 28 Extruder Tracking Control EEN 28 Control Relay Connection E 28 Extruder Tracking Installation and Setup sess 29 Field Control Programming EE 30 Resetting the Unit to Un Programmed State sss 31 JP1 Program Enable Jumper E 31 Programming Step by Step Guide 31 Extruder Tracking Control Application Notes 32 CHAPTER 5 PROGRAM PARAMETER DESCRIPTIONS 34 5 1 Defining Program BS EE 34 CHAPTER 6 MAINTENANCE ee eeeee enne 39 6 1 Preventative Maintenance Schedule esee 39 6 2 Preventative E ahn Eer 40 Material Cleanout CHangeDVel utto d eoo ede dides stile Soo bU been
38. ing machine shot cycle when the additive feeder motor is running in AUTO mode Additive Feeders Chapter 4 Operation 22 of 55 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 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 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 19 for specific calibration instructions 1 Set the timer to the desired calibratio
39. ipment 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 Cove
40. isplayed 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 t
41. ith cycled processes like injection molding e 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 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 2 Functional Description 12 of 55 2 5 Extruder Following Feature e 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 e 0 3 cubic foot capacity hopper with slide gate allows for rapid change of additives Supply Hopper Covers e Hopper mounting cutout for vacuum receivers e Hopper loader mounting cutout for hopper loaders e Blank cover available for custom cutout 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 Advi
42. itive Feeders connected Do not wear gloves or loose clothing when working near the auger assembly 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 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 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 Clean the interior of the supply hopper and any additive remaining in the calibration or cleanout hatches 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 maint
43. l 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 Valu
44. mbers 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 Chapter 1 Safety v of 55 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 EN A HR RR NN EN EN Read and follow these operation and installation instructions when
45. mper 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 Additive Feeders Chapter 4 Operation 25 of 55 7 10 11 12 13 14 15 16 17 18 19 20 2 22 23 Install the enclosure cover 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 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 Use the Up and Down arrow buttons to navigate to the desired parameter 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 Use the Up and Down arrow buttons to change the parameter s
46. n 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 e OFF stops the auger motor e AUTO starts normal automatic operation e 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 mold
47. n 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 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 23 of 55 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 contro
48. ne the desired additive feeder setpoint of extruder master screw RPM To determine this you must know e Total extruder feedrate lbs hr e The RPM of the extruder screw at that feedrate e The letdown ratio of the additive or e The additive feedrate required at that letdown ratio total feedrate X letdown ratio e The additive feedrate RPM needed to achieve this feedrate as determined by the calibration procedure Extruder Tracking Equation Set Point rom of feeder rom of extruder x 100 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 Feeder auger rpm needed for 35 Ibs 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 Additive Feeders Chapter 4 Operation 29 of 55 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
49. ness 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 d
50. o 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 45V 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
51. oles 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 Boltthe 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 15 of 55 3 3 Electrical Connections When making electrical connections to your additive feeder ensure that you take into consideration and make arrangements for the following e A qualified electrician should make all electrical connections e Fulfill all national state and local safety and electrical code requirements e 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 e 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 e Make sure all electrical connections are tight Main Pow
52. on 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 ju
53. 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 Ent
54. ontrol 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 Additive Feeders Chapter 4 Operation 28 of 55 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 N of Pulses per Revolution of the Feeder Screw 3 AW If not counted directly from screw multiply by a fudge factor to get the pulses per extruder screw rpm 3 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 Determi
55. rate 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 a
56. red 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 e Stainless steel augers available in 12 34 1 1 1 4 and 1 1 2 sizes e Augers insert assemblies are interchangeable without tools e UHMW polyethylene auger insert is durable and easily cleaned e Calibration hatch opens without tools 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 d
57. s 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 nu
58. sory or process interrupt capability e Alarm silence acknowledge button Drawer Magnet e Removes tramp metal from the process stream 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 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 Additive Feeders Chapter 2 Functional Description 13 of 55 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 incorpo
59. ssistance 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 the packing list In addition to the equipment itself you should have M Bill of lading M Packing list Kl Operating and Installation packet V Electrical schematic and panel layout drawings Kl Component instruction manuals if applicable 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 parts and service department immediately at 262 641 8610 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 T SAFETY ege eege Ee EES eg V 14 Howto Use This Manual rnt ener e e eoe epp Rd Fee EH ERR EE det V Safety Symbols Used in this Manual seen V 1 2 Warnings and Pr eau lonis nde teet e Ex eR dep dee edu t ae mex rit e vi T3 TROSDODSIDIIDY E EE vii General HesponsiDIIV c cote eut orta Dados dde oes ies ege SE vii erageet eessen eege viii Additive Feeder Safety e EE ix Maintenance HesponsiDIlly E Ix Reporting a Safety Defect ee ceteras alo lato bios X CHAPTER 2 FUNCTIONAL DESCRIPTION
60. stallation 20 of 55 3 5 Initial Start up Pre Startup Checks M 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 H HRH RR RR 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 Additive Feeders Chapter 3 Installation 21 of 55 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 whe
61. t 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 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 tim
62. tely report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e 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 e Before you start the feeder check the 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 Atthe 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 e 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 e 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 e D
63. tes 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 34 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
64. tly e Breakdown of shop morale Costly damage to equipment e 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 Immedia
65. wn 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 ee EEEIEE mem eee eee sleeve and nopper cee ee EUN GIA EN EE LET I a FREE ERE ERES LEN EI DN RT ONT ERE ed up zu EO EJ Every month Jan Feb Mar Apr May Jun Jul Aug 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 Add
66. y 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 a procedure E Remove the brush Make note of the direction of the tapered end of the brush face 2 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 tha

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