Sterling Welder 8820027400 User Manual

SF Series Additive Feeders  
Part Number: 882.00274.00  
Bulletin Number: BF2-605  
Effective: 10/31/05  
Write Down Your Serial Numbers Here For Future Reference:  
_________________________  
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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 2005  
All rights reserved.  
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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 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  
; 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.  
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Table of Contents  
CHAPTER 1: SAFETY .................................................................V  
1-1  
How to Use This Manual ............................................................................................. v  
Safety Symbols Used in this Manual.....................................................................v  
Warnings and Precautions ......................................................................................... vi  
Responsibility .............................................................................................................vii  
General Responsibility......................................................................................... vii  
Operator Responsibility.......................................................................................viii  
Maintenance Responsibility.................................................................................. ix  
Reporting a Safety Defect .................................................................................... ix  
1-2  
1-3  
CHAPTER 2: FUNCTIONAL DESCRIPTION.............................10  
2-1  
2-2  
2-3  
Models Covered in This Manual................................................................................10  
General Description...................................................................................................10  
Standard Features.....................................................................................................10  
Mechanical Features...........................................................................................10  
Electrical Features...............................................................................................11  
Controller Features..............................................................................................11  
Options......................................................................................................................11  
Accessories...............................................................................................................12  
Safety Devices and Interlocks...................................................................................13  
2-4  
2-5  
2-6  
CHAPTER 3: INSTALLATION ...................................................15  
3-1  
3-2  
3-3  
3-4  
Uncrating the Equipment...........................................................................................15  
Rigging and Placing the Additive Feeder ..................................................................15  
Electrical Connections...............................................................................................16  
Setup Procedures......................................................................................................17  
Determining the Desired Feed Rate....................................................................17  
Calibration Procedure..........................................................................................19  
Initial Start-up ............................................................................................................21  
Pre-Startup Checks.............................................................................................21  
Starting Up the Additive Feeder ..........................................................................21  
Shutting Down the Additive Feeder.....................................................................21  
3-5  
CHAPTER 4: OPERATION ........................................................22  
4-1  
4-2  
Start-up......................................................................................................................22  
Controller Description and Operation........................................................................22  
Identifying Control Panel Indicator Lights and Switches on the Controller..........22  
Timer/Counter Control Operation (Injection Molding Applications) .....................23  
Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications)..............24  
Dual Setpoint Control Operation (2 Component Applications) ............................25  
Extruder Tracking Control ...................................................................................26  
Extruder Tracking Installation and Setup.............................................................26  
Field Control Programming..................................................................................28  
Additive Feeder Control Factory Defaults............................................................31  
Shutting Down the Additive Feeder...........................................................................31  
4-3  
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CHAPTER 5: MAINTENANCE...................................................32  
5-1  
5-2  
Preventative Maintenance Schedule.........................................................................32  
Preventative Maintenance.........................................................................................33  
Material Cleanout/Changeover............................................................................33  
Corrective Maintenance ............................................................................................34  
Auger Assembly Changeover..............................................................................34  
Motor Brush Replacement...................................................................................35  
5-3  
CHAPTER 6: TROUBLESHOOTING........................................36  
6-1  
Introduction................................................................................................................36  
CHAPTER 7: APPENDIX ..........................................................38  
7-1  
Warranty....................................................................................................................38  
Warranty Specifications.........................................Error! Bookmark not defined.  
Warranty Restrictions............................................Error! Bookmark not defined.  
Warranty Liabilities................................................Error! Bookmark not defined.  
Customer Responsibilities.....................................Error! Bookmark not defined.  
Optional Components................................................................................................39  
Technical Specifications............................................................................................40  
Annex B Information............................................................................................40  
Drawings and Diagrams............................................................................................41  
Spare Parts List.........................................................................................................44  
Returned Material Policy ...........................................................................................48  
Credit Returns .....................................................................................................48  
Warranty Returns ................................................................................................48  
Safety Tag Information..............................................................................................48  
Additive Feeder Safety Tags...............................................................................48  
Additive Feeder Identification (Serial Number) Tag ..................................................49  
Technical Assistance.................................................................................................49  
Parts Department ................................................................................................49  
Service Department.............................................................................................49  
Sales Department................................................................................................49  
Contract Department...........................................................................................49  
7-2  
7-3  
7-4  
7-5  
7-6  
7-7  
7-8  
7-9  
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
additive feeder. The purpose is to assist you in applying efficient, proven techniques that  
enhance equipment productivity.  
This manual covers only light corrective maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and safety  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the additive feeder. We can also provide the assistance of a factory-trained technician to  
help train your operator(s) for a nominal charge. This section includes instructions, checks,  
and adjustments that should be followed before commencing with operation of the additive  
feeder. These instructions are intended to supplement standard shop procedures performed  
at shift, daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the additive feeder safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that your additive feeder provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, parts lists, and  
available options. A spare parts list with part numbers specific to your machine is provided  
with your shipping paperwork package. Refer to this section for a listing of spare parts for  
purchase. Have your serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,  
will result in death or serious injury.  
WARNING! WARNING indicates a potentially hazardous situation or practice that, if  
not avoided, could result in death or serious injury.  
Caution!  
CAUTION indicates a potentially hazardous situation or practice that, if  
not avoided, may result in minor or moderate injury or in property damage.  
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1-2 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes. This may include, but  
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international  
regulations.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
; Read and follow these operation and installation instructions when installing,  
operating, and maintaining this equipment. If these instructions become  
damaged or unreadable, additional copies are available from the manufacturer.  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Work only with approved tools and devices.  
; Disconnect and/or lock out power before servicing or maintaining the equipment.  
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
; Operate this equipment within design specifications.  
; DO NOT use the additive feeder in an explosive atmosphere.  
; DO NOT use additive feeder outdoors or in wet environments. Moisture will  
damage the motor and can create an electric shock hazard.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
; Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
; Use 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.  
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Chapter 1: Safety  
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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 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 is always affected in a  
negative way following an accident. The following are some of the ways that accidents can  
affect your production:  
Loss of a skilled operator (temporarily or permanently)  
Breakdown of shop morale  
Costly damage to equipment  
Downtime  
An effective safety program is responsible and economically sound.  
Organize a safety committee or group, and hold regular meetings. Promote this group from  
the management level. Through this group, the safety program can be continually reviewed,  
maintained, and improved. Keep minutes or a record of the meetings.  
Hold daily equipment inspections in addition to regular maintenance checks. You will keep  
your equipment safe for production and exhibit your commitment to safety.  
Please read and use this manual as a guide to equipment safety. This manual contains safety  
warnings throughout, specific to each function and point of operation.  
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Chapter 1: Safety  
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Operator Responsibility  
The operator’s responsibility does not end with efficient production. The operator usually has  
the most daily contact with the equipment and intimately knows its capabilities and  
limitations.  
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or  
through a casual attitude toward machinery formed over a period of months or years. Your  
employer probably has established a set of safety rules in your workplace. Those rules, this  
manual, or any other safety information will not keep you from being injured while operating  
your equipment.  
Learn and always use safe operation procedures. Cooperate with co-workers to promote safe  
practices. Immediately report any potentially dangerous situation to your supervisor or  
appropriate person.  
REMEMBER:  
NEVER place your hands or any part of your body in any dangerous location.  
NEVER operate, service, or adjust the feeder without appropriate training and first  
reading and understanding this manual.  
NEVER try to pull material out of the feeder with your hands while it is running!  
Before you start the feeder check the following:  
Remove all tools from the feeder;  
Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the  
hopper area;  
If your feeder has been inoperative or unattended, check all settings before starting the  
unit.  
At the beginning of your shift and after breaks, verify that the controls and other  
auxiliary equipment are functioning properly.  
Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,  
or remove safety guards. Such alteration is not only unsafe, but will void the warranty  
on your equipment.  
When changing control settings to perform a different mode of operation, be sure  
selector switches are correctly positioned. Locking selector switches should only be  
adjusted by authorized personnel and the keys removed after setting.  
Report the following occurrences IMMEDIATELY:  
unsafe operation or condition  
unusual feeder action  
leakage  
improper maintenance  
NEVER stand or sit where you could slip or stumble into the feeder  
while working on it.  
DO NOT wear loose clothing or jewelry, which can be caught while working on a  
feeder. In addition, cover or tie back long hair.  
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Clean the feeder and surrounding area DAILY, and inspect the machine for loose,  
missing or broken parts.  
Shut off power to the feeder when it is not in use. Turn the switch to the OFF  
position, or unplug it from the power source.  
Maintenance Responsibility  
Proper maintenance is essential to safety. If you are a maintenance worker, you must make  
safety a priority to effectively repair and maintain equipment.  
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric  
supplies and all accessory equipment at the machine, and disconnect and lockout electrical  
power. Attach warning tags to the disconnect switch.  
When you need to perform maintenance or repair work on equipment above floor level, use a  
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your  
equipment, use it. The work platform should have secure footing and a place for tools and  
parts. DO NOT climb on equipment, machines, or work from ladders.  
If you need to repair a large component, use appropriate handling equipment. Before you use  
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)  
be sure the load does not exceed the capacity of the handling equipment or cause it to become  
unstable.  
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using  
them to lift a load.  
Be sure that all non-current carrying parts are correctly connected to earth ground with an  
electrical conductor that complies with current codes. Install in accordance with national and  
local codes.  
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.  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides operation, installation, and maintenance instructions for 1 and 2  
component additive feeders. Model numbers are listed on the serial tag. Make sure you know  
the model and serial number of your equipment before contacting the manufacturer for parts  
or service.  
Our additive feeders are designed to precisely feed up to two components before being used  
in the injection molding, blow molding or extrusion processes. Additive Feeders are  
configured to meet the specific requirements stated by the Customer at the time of purchase.  
2-2 General Description  
Our additive feeder is a highly accurate unit designed to feed one or two additives into a  
stream of virgin plastic pellets prior to injection molding, blow molding, or extrusion. Such  
additives may include color, regrind, or other free-flowing pelletized or granular materials.  
The additive feeder may also be appropriate for other applications. Consult the manufacturer  
for additional information.  
2-3 Standard Features  
Mechanical Features  
Transport Tube  
Stainless steel augers available in ½”, ¾”, 1”, 1-1/4” and 1-1/2” sizes  
Augers/insert assemblies are interchangeable without tools  
UHMW polyethylene auger insert is durable and easily cleaned  
Calibration hatch opens without tools  
Cleanout hatch below the flood zone opens without tools and allows the supply hopper  
to dump completely.  
Lightweight aluminum casting  
Main Throat  
Low profile design adds only 6 inches to supply system headroom requirements  
Accomodates one or two transport assemblies  
Sturdy steel construction  
Supply Hopper  
1-cubic-foot capacity (45 pounds @ 45 lb./cubic foot)  
Design based on dynamic/static material flow characteristics  
Angled hopper geometry allows use with 60º machine supply hoppers  
Easy, fast, and complete cleanout  
Sight glasses give visual level indication  
Manual fill cover standard  
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Motor Assembly  
Quick release swing-away motor mount speeds auger/motor changes and cleanout  
Permanently lubricated  
Replaceable motor brushes  
Electrical Features  
Motor Assembly  
Continuous service fractional horsepower DC motor.  
Hall Effect sensor transmits RPM to microprocessor control  
115/1/60 supply voltage  
Controller Features  
Closed-loop control constantly monitors feedback from the auger motor RPM sensor  
for high accuracy and repeatability. Feed rates remain stable during main power  
supply voltage fluctuations.  
Remote control mounting capability permits mounting the control panel up to 9 feet  
from the feeder.  
Field-programmable display permits viewing in rpm, pounds per hour, kilos per hour,  
etc., as well as high/low limits.  
Automatic and manual/calibration operation modes.  
2-4 Options  
Options marked with “*” indicate options that can be factory installed or retrofitted in the  
field.  
Special Voltage  
230/1/50 VAC  
Timer/Counter Control  
Designed for use with cycled processes like injection molding  
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.  
Batch counter provides inventory management information  
Calibration feature allows precise, repeatable sampling during setup  
Timer/Elapsed Timer Control  
Designed for use with continuous processes like extrusion  
Elapsed timer provides inventory management information  
Calibration feature allows precise, repeatable sampling during setup  
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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  
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.  
Feature is enabled with a DIP switch adjustment.  
Expanded Supply Hopper  
2.0 cubic foot capacity  
Supply Hopper Covers  
Hopper mounting cutout for vacuum receivers  
Hopper loader mounting cutout for hopper loaders  
Additional Auger Assemblies  
Switch augers for changing process throughputs  
Mounting Adapters  
Special main throat and flanges can eliminate transitions and accommodate different  
machine hoppers  
2-5 Accessories  
Low Level Alarm  
Audible/visual alert to allow supply hopper level to avoid feeding straight resin into  
the processing machine  
Remote mount  
Advisory or process interrput capability  
Alarm silence/acknowledge button  
Drawer Magnet  
Removes tramp metal from the process stream  
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2-6 Safety Devices and Interlocks  
This section includes information on safety devices and procedures that are inherent to the  
additive feeder. This manual is not intended to supersede or alter safety standards established  
by the user of this equipment. Instead, the material contained in this section is recommended  
to supplement these procedures in order to provide a safer working environment.  
At the completion of this section, the operator and maintenance personnel will be able to do  
the following:  
Identify and locate specific safety devices.  
Understand the proper use of the safety devices provided.  
Describe the function of the safety device.  
Safety Circuit Standards  
Safety circuits used in industrial systems protect the operator and maintenance personnel  
from dangerous energy. They also provide a means of locking out or isolating the energy for  
servicing equipment.  
Various agencies have contributed to the establishment of safety standards that apply to the  
design and manufacture of automated equipment. The Occupational Safety and Health  
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the  
organizations that have joined with the plastics industry to develop safety standards.  
Every effort has been made to incorporate these standards into the design of the additive  
feeder; however, it is the responsibility of the personnel operating and maintaining the  
equipment to familiarize themselves with the safety procedures and the proper use of any  
safety devices.  
Fail Safe Operation  
If a safety device or circuit should fail, the design must be such that the failure causes a  
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch  
must be held closed with the device it is to protect. If the switch fails, it will go to the open  
condition, tripping out the safety circuit.  
At no time should the safety device fail and allow the operation to continue. For  
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should  
not be able to run.  
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Safety Device Lock-Outs  
Some safety devices disconnect electrical energy from a circuit. The safety devices that are  
used on these additive feeders are primarily concerned with electrical power disconnection  
and the disabling of moving parts that may need to be accessed during the normal operation  
of the machine.  
Some of the safety devices utilize a manual activator. This is the method of initiating the  
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable  
handle, there may be a location for a padlock. Personnel servicing the equipment should  
place a padlock in the lockout handle.  
In addition to the safety devices listed above, these additive feeders are equipped with a line  
cord plug. This allows the operator or maintenance personnel to unplug the additive feeder  
from its power source and tag it out. The plug can then be tagged with any number of  
approved electrical lockout tags available at most electrical supply stores.  
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)  
sources prior to servicing or cleaning the additive feeder. Failure to do so may result in  
serious injury. No one but the person who installed the lockout may remove it.  
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Chapter 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. Use a pry bar to remove the blocks securing the unit to the skid.  
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the  
skid from the unit.  
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  
access.  
3. Clamp the main throat to the machine with locking pliers.  
4. Bolt the 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.  
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3-3 Electrical Connections  
When making electrical connections to your additive feeder, ensure that you take into  
consideration and make arrangements for the following:  
A qualified electrician should make all electrical connections.  
Fulfill all national, state, and local safety and electrical code requirements.  
The serial tag lists voltage, phase, and amp draw information:  
Line voltage must be within plus or minus ten percent (±10%) of the  
voltage listed on the serial tag, or damage may occur.  
Install a fused disconnect with a lockout feature in the power main leading to the  
additive feeder if the unit will be wired directly to a power main.  
Make sure all electrical connections are tight.  
Main Power Connection  
The control is shipped pre-wired and attached to the additive feeder. Standard controls are  
supplied with a power cord with the plug wired to the control unit, ready to plug into an  
appropriately grounded three-prong receptacle.  
Control Relay Connection  
To interlock the additive feeder operation to an injection molding machine, extruder, etc.,  
remove jumper (J1) from the terminal block in the control enclosure and wire in the control  
relay signal from the processing machine. 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.  
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3-4 Setup Procedures  
This section provides the procedures necessary for configuring your additive feeder.  
Configuration of your additive feeder includes determining the desired feed rate and  
calibrating the additive feeder. We recommend that you carry out these procedures in the  
order given here.  
Note: Before carrying out these procedures, install all equipment as  
described in this section.  
Determining the Desired Feed Rate  
The additive feed rate is the desired amount of additive to be introduced into the process  
stream per hour. To determine the feed rate, follow the procedure in this section. If the  
desired feed rate is known, go to the calibration procedure in the next section. The charts in  
figures 1 and 2 provide conversion and rate charts to assist you in your calculations.  
For Cyclical Processing (Injection Molding, etc.)  
To set up an additive feeder for cyclical processing, you need to know shot size, recovery  
time, and the letdown ratio.  
Cyclical Processing Equation:  
Shot Size (oz)  
Recovery time (sec) x Letdown (ratio or %) x 225 = Feed Rate (lbs./hr.)  
Example:  
Shot size = 8 ounces  
Recovery time = 5 seconds  
Letdown ratio = 20:1  
8 oz./5 sec. X 1/20 = 0.08 = Desired feed rate  
To convert to lbs./hr.: 0.08 oz/sec x 225 = 18 lbs./hr.  
For Continuous Processing (Extrusion, etc.)  
To set up an additive feeder for continuous processing, you need to know the total process  
throughput and the desired additive percentage or letdown ratio.  
Continuous Processing Equation:  
Total throughput (lbs./hr.) x percentage of additive = Feed rate  
Example:  
Total throughput = 100 pounds per hour  
Percentage of additive = 2%  
100 lbs./hr. x 0.02 = 2 lbs./hr. feed rate  
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Figure 1: Conversion Chart  
Multiply  
Ounces per Second  
Grams  
Ounces  
Seconds  
By  
To obtain  
Pounds per Hour  
Ounces  
Pounds  
Hours  
225  
0.035  
0.0625  
0.00028  
Figure 2: Rate Chart  
110 lb/hr  
110  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
0
55 lb/hr  
25 lb/hr  
7 lb/hr  
4 lb/hr  
7 lb/hr  
1 1/2 lb/hr  
3/4" auger  
1/2 lb/hr  
1/2" auger  
1" auger  
1 1/4" auger  
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Calibration Procedure  
This procedure allows the operator to precisely adjust additive feed rates.  
Caution!  
Never put hands or tools in or near the auger assembly when power is  
connected.  
Do not wear gloves or loose clothing during calibration. The auger is  
exposed when the calibration or cleanout hatches are open.  
Equipment Needed:  
Scale  
Sample container  
Timer- stopwatch, watch/clock w/second hand  
Procedure  
1. Close cleanout and calibration hatches.  
2. Fill the additive supply hopper.  
3. Weigh the empty sample container.  
4. Swing open the calibration hatch near the main throat.  
5. Set the controller to a desired RPM.  
6. Place the sample container below the calibration hatch.  
7. Hold the three-position motor switch in the Manual position for about a minute.  
This lets the new setpoint stabilize and fills the auger flights with material. Discard  
the first sample.  
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 the sample container. Subtract the weight of the container and multiply by 60  
to determine the pounds per hour feed rate.  
10. Adjust the auger rpm and repeat the calibration process until the desired feed rate is  
achieved.  
Note: To speed the calibration procedure, reduce trial and error auger rpm  
settings and zero in on the desired feed rate. Chart the calculated feed  
rates from a few rpm settings on graph paper. Draw a straight line  
between the coordinates to establish a customized feed rate curve for  
the actual operating conditions. A sample graph is provided on the  
next page; graph paper is included in the back of this manual for use  
with your feeding processes.  
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Examples:  
This example shows how to extrapolate a desired feed rate of 3 lbs./hr., based on the feed  
rates of 3 trial rpm settings.  
Observed Feed Rates  
Sample 1 = 2 pounds per hour @ 20 rpm  
Sample 2 = 4 pounds per hour @ 40 rpm  
Sample 3 = 6 pounds per hour @ 60 rpm  
In this example, a feed rate of 3 lbs./hr. would be about 30 rpm.  
8
Calculated 7  
feed rates  
(lbs/hr)  
@ the  
3
6
5
4
3
2
1
0
2
trial RPM  
4
1
10 20 30 40 50 60 70  
Trial RPM settings  
0
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3-5 Initial Start-up  
Pre-Startup Checks  
; Are all the electrical connections correct, secure and to code?  
; Is the auger insert locked in place?  
; Are the motor and auger properly coupled and the motor mount locked in place?  
; Are the cleanout and calibration hatches shut and secured?  
; Are all tools, hardware, etc., cleared from the feeder?  
; Is the processing machine ready for operation?  
; Is the control relay connection to the processing machine properly installed?  
; Is there an adequate supply of additive in the supply hopper?  
; Is the supply system (if installed) ready for operation?  
Starting Up the Additive Feeder  
1. Turn the power switch ON.  
2. Set the desired feed rate on the RPM display using the up or down arrows.  
3. Flip the motor switch to AUTO.  
If the additive feeder is installed 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.  
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Chapter 4: Operation  
4-1 Start-up  
1. Turn the power switch ON.  
2. Set the desired feed rate on the RPM display using the up or down arrows.  
3. Flip the motor switch to AUTO.  
If the additive feeder is installed correcly, it should begin operation at the desired RPM when  
the processing machine screw is in operation.  
4-2 Controller Description and Operation  
Identifying Control Panel Indicator Lights and Switches on the Controller  
Switches  
Power Switch. This switch turns the control ON and OFF.  
Motor Switch. This switch has three (3) positions:  
OFF stops the auger motor.  
AUTO starts normal automatic operation.  
MANUAL operates the auger at the set point as long as the switch is held in this  
position. Use this feature when calibrating the feeder or during cleanout.  
Indicator Lights  
Motor Light. This indicator lights when the auger motor is turning.  
Auger Speed. This LED displays the auger speed setpoint.  
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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. Set the timer to the desired calibration period, using the round timer keys (See the  
timer information sheet for additional information.).  
2. Start the additive feeder by flipping the MOTOR switch to the MANUAL position.  
3. When the timer times out, the feeder automatically stops.  
Used as a Cycle Override Safety Timer  
This component of the controller allows the operator to override the molding machine shot  
cycle when the additive feeder motor is running in AUTO mode.  
Procedure  
1. Time the duration of feeder operation during a typical Injection molding machine  
shot cycle.  
2. Set the timer to a slightly longer value.  
3. Start the additive feeder by flipping the motor switch to the AUTO position.  
4. If the timer times out because of a process flow problem, the feeder will  
automatically stop.  
5. Reset the power switch.  
Counter Module  
The counter module may be used as an inventory management aid and can also confirm the  
total cycles between reset independent of the IMM’s control. Every IMM cycle will  
increment the display value. The counter module has battery-backed memory and will not  
lose count if the electrical power is interrupted.  
Press the RESET button to reset the counter.  
Note: Remove the jumper on the back of the module to lock out the reset  
button. Replace the jumper to restore reset button operation.  
Disconnect the power before moving the jumper.  
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Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications)  
The Timer/Elapsed Timer control is designed for use with continuous processes like  
extrusion and blow molding and features a timer and elapsed time module.  
Timer Module  
This feature of the controller assists in calibration of the additive feeder (See Page 20 for  
specific calibration instructions.).  
1. Set the timer to the desired calibration period, using the round timer keys (see the  
timer information sheet for additional information.)  
2. Start the additive feeder by flipping the motor switch to the MANUAL position.  
3. When the timer times out, the feeder will automatically stop.  
Elapsed Time Module  
The elapsed time module may be used as an inventory management aid for continuous  
processing operations.  
The timer module measures the time the additive feeder control receives the monitored  
control relay signal from the extruder/blow molder machine. The timer module has a battery-  
backed memory and will not lose the elapsed time of operation if the electrical power is  
interrupted.  
Press the RESET button to reset the counter.  
Note: Remove the jumper on the back of the module to lock out the reset  
button. Replace the jumper to restore reset button operation.  
Disconnect power before moving the jumper.  
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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 motor control. If the supply  
of regrind drops below the proximity switch, the regrind feeder stops and the other feeder  
switches to the Set Point #2 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 #1 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.  
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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 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:  
Inductive proximity sensors to sense gear teeth.  
Magnetic pickups to sense affixed magnets.  
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 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 ➁  
If not 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.  
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6. Determine the desired additive feeder setpoint (% of extruder (master) screw RPM).  
To determine this, you must know:  
Total extruder feedrate (lbs./hr.).  
The RPM of the extruder screw at that feedrate.  
The letdown ratio of the additive (% or :).  
The additive feedrate required at that letdown ratio (total feedrate X  
letdown ratio).  
The additive feedrate RPM needed to achieve this feedrate (as  
determined by the calibration procedure).  
Extruder Tracking Equation:  
Set Point = (rpm of feeder / rpm of extruder) x 100  
Example:  
Total extruder feedrate = 500 pounds per hour  
Extruder screw rpm for 500 lbs/hr = 50 rpm  
Additive letdown percentage = 7%  
Additive feedrate = 500 X 0.07 = 35 lbs./hr.  
Feeder auger rpm needed for 35 lbs./hr. = 44 rpm (as the calibration procedure has  
shown)  
Assuming this, set point = 44 rpm/50 rpm x 100 = 88 or 88% of the extruder screw speed.  
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Field Control Programming  
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.  
Equation:  
CONSTANT = 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.  
Motor 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.  
Example 1:  
Equation:  
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:  
How the factory pre-set constant was calculated:  
Equation:  
Constant = (1500) / (25.2 x 2) = 30.0  
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Programming Mode  
The motor will stop when in Programming mode.  
1. Make sure DIP switches 1 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. Use the Up or Down buttons to change the decimal point as desired. Use 0 for NO  
decimal point.  
4. When finished, 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 DIP 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. Use the 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 is set to the slowest speed when you exit the Programming Mode.  
Programming for Follower Operation  
1. Enter Programming Mode, then turn DIP switches 5, MASTER/FOLLOWER  
SELECT, and 1, PROGRAM CONSTANT, to ON.  
2. Set constant 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.  
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Viewing or Changing the Program Minimum Setting  
1. Enter the programming mode, then flip DIP switch 2, Program Minimum Setting,  
to ON.  
2. The current value for the lower limit FACTORY SETTING = 0 will appear in the  
LED display.  
3. Use the Up or Down buttons to change the lower limit, as desired.  
4. When finished, flip DIP switch 2 to OFF.  
5. The display should read PROG.  
Viewing or Changing the Program Maximum Setting  
1. Enter the programming mode, then flip DIP switch 3, PROGRAM MAXIMUM  
SETTING to ON.  
2. The current value for the upper limit FACTORY SETTING = 70 will appear in the  
LED display.  
3. Use the Up or Down buttons to change the upper limit, as desired.  
4. When finished, flip DIP switch 3 to OFF.  
5. The display should read PROG.  
Exiting Programming Mode and Returning to Run Mode  
1. 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).  
2. Make sure DIP switches 1 through 4 are OFF.  
3. If satisfied with the programmed values, flip DIP switch 7 to OFF.  
4. Control should begin to operate normally, using the values and modes selected.  
Figure 3: DIP Switch Function Table  
Switch 1  
Switch 2  
Switch 3  
Switch 4  
Switch 5  
Switch 6  
Switch 7  
Switch 8  
Program Constant  
Program Minimum Setting  
Program Maximum Setting  
Decimal Select  
Master/Follower Select  
Do Not Use – Set to OFF  
Program/Run Select  
0 – 4 = Decimal Points  
OFF = Master ON = Follower  
OFF = Run ON = Program  
Do Not Use – Set to OFF  
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Additive Feeder Control Factory Defaults  
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!  
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  
Switch 1  
Switch 2  
Switch 3  
Switch 4  
Switch 5  
Variable  
Auger RPM Constant  
Program Minimum  
Program Maximum  
Decimal Place  
Pre-set  
30.0  
0.0  
70.0  
0.3  
Master/Follower Select  
Standard Control  
OFF  
ON  
Optional Extruder  
Tracking Control  
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.  
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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.  
System model #  
Every week  
Serial #  
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
By  
Inspect auger,  
sleeve and hopper  
throat. Clean if  
dirty.  
Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec  
Lock out electrical  
power and inspect  
electrical wiring for  
integrity.  
Visually inspect the  
operation of motor  
and auger while it  
is operatng.  
- Photocopy this page for your maintenance records -  
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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!  
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.  
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5-3 Corrective Maintenance  
This section provides you with the information necessary to correct or repair any issues  
which might appear during the normal operation of your additive feeder. Although we have  
listed how to perform these procedures, it is recommended that you call the Service  
Department to have any in-depth maintenance performed.  
Auger Assembly Changeover  
Our additive feeder auger assemblies may be removed and installed without tools. All auger  
sizes are interchangeable.  
Caution!  
Disconnect and/or lock out electrical power before removing an auger  
assembly or performing any service or maintenance.  
Removing Auger Assembly  
1. Empty the supply hopper by swinging open the cleanout hatch.  
2. Disengage the motor assembly from the auger by removing the motor mount linchpin  
and swinging out the motor.  
3. Pull the auger out.  
4. Swing open the calibration hatch.  
5. Release the UHMW auger insert by pulling out the spring loaded 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 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.  
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Motor Brush Replacement  
The two (2) motor brushes should be replaced when they are worn down to less than 1 inch in  
length. Replacement brushes are “pre-worn” by the manufacturer and require no break-in  
period.  
Caution!  
Disconnect power to the Additive Feeder before changing the motor  
brushes.  
1. Remove a brush cap screw near the back of the motor.  
Caution!  
The motor brushes are spring loaded. Use care to avoid eye injury when  
removing the cap screw. Wear safety glasses when performing this  
procedure.  
2. Remove the brush. Make note of the direction of the tapered end of the brush face.  
3. Insert the new brush (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.  
5. Repeat the above steps for the other brush.  
The motor is now ready for use.  
Figure 5: Replacement Motor Brush Part Numbers  
Part Number  
A0541239  
A053426-BS  
Description  
115 VAC controls, motor plate marked 90 VDC, 1/20 HP  
115 VAC controls, motor plate marked 90 VDC, 1/10 HP  
Additive Feeders  
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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  
necessary, refer to the parts catalog section.  
Problem  
Possible cause  
Corrective action  
No power to the control.  
Power switch is off.  
Fuse is blown.  
Plug in control.  
Turn power on.  
Replace fuse.  
Clear.  
Auger is jammed.  
Loose control wiring.  
Power switch has failed.  
Motor switch has failed.  
Feeder is wired incorrectly to  
the processing machine.  
Control relay has failed.  
Motor control has failed.  
Motor brushes are worn.  
Controller is in the program  
mode. Display reads PROG.  
Optional timer set incorrectly.  
Optional timer mode set  
incorrectly.  
Tighten.  
Replace.  
Replace.  
Refer to the control enclosure  
wiring diagram.  
Replace.  
Replace.  
Replace.  
Feeder will not run with switch  
in AUTO or MANUAL position.  
Reset DIP Switch 7.  
Reset timer.  
Set operation mode to H and  
configuration to d.  
Replace.  
Optional timer has failed.  
Additive Feeders  
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Problem  
Possible cause  
Corrective action  
Remove jumper and wire the  
terminals to the processing  
machine relay.  
Field contact jumper (J1) has not  
been removed. AUTO MODE.  
Field contact to the processing  
machine has failed.  
Check wiring/check the relay on  
the processor.  
Motor switch has failed.  
Field contact to process machine  
missing or loose.  
Replace.  
Motor will not stop.  
Correct.  
Control relay has failed.  
Motor control has failed.  
Optional timer set incorrectly.  
Optional timer has failed.  
Signal from motor speed sensor  
missing.  
Replace.  
Replace.  
Reset.  
Replace.  
Secure the sensor connections.  
Motor runs only at maximum  
speed.  
Motor control has failed.  
Motor speed sensor has failed.  
Motor speed sensor magnet  
misaligned.  
Replace.  
Replace.  
Adjust.  
Intermittent signal from motor  
speed sensor.  
Secure the sensor connections.  
Motor speed not constant.  
Motor speed sensor has failed.  
Motor control has failed.  
Material flow problem.  
Feeder was not cleaned  
adequately prior to operation.  
Replace.  
Replace.  
Inspect for blockage, etc.  
See Section 5-2 on Page 34 for  
cleanout instructions.  
Additive is contaminated by  
color from previous run.  
Other service problems or questions can be answered by contacting the Service  
Department.  
Additive Feeders  
Chapter 6: Troubleshooting  
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Chapter 7: Appendix  
7-1 Warranty  
The manufacturer warrants all equipment manufactured by it to be free from defects in  
workmanship and material when used under recommended conditions. The company’s  
obligation is limited 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.  
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.  
The company is not liable for any incidental, consequential, or special damages or expenses.  
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.  
Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is  
the responsibility of the purchaser.  
The company neither assumes nor authorizes any other persons to assume for it any liability  
in connection with the sale of its equipment not expressed in this warranty.  
Many types of the manufacturer’s equipment carry an additional one-year service policy.  
Consult your sales representative for specific details.  
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7-2 Optional Components  
The following is a list of options which your Additive Feeder may have been equipped with:  
Special Voltage  
230/1/50 VAC  
Timer/Counter Control  
Designed for use with cycled processes like injection molding  
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.  
Batch counter provides inventory management information  
Calibration feature allows precise, repeatable sampling during setup  
Timer/Elapsed Timer Control  
Designed for use with continuous processes like extrusion  
Elapsed timer provides inventory management information  
Calibration feature allows precise, repeatable sampling during setup  
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  
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.  
Feature is enabled with a DIP switch adjustment.  
Expanded Supply Hopper  
2.0 cubic foot capacity  
Supply Hopper Covers  
Hopper mounting cutout for vacuum receivers  
Hopper loader mounting cutout for hopper loaders  
Additional Auger Assemblies  
Switch augers for changing process throughputs  
Mounting Adapters  
Special main throat and flanges can eliminate transitions and accommodate different  
machine hoppers  
Additive Feeders  
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7-3 Technical Specifications  
Annex B Information  
The following design information is provided for your reference:  
1. No modifications are allowed to this equipment that could alter the CE compliance  
2. Ambient temperature:  
3. Humidity range:  
4. Altitude:  
0 degrees Celsius – Maximum (104 degrees Fahrenheit)  
50% relative humidity  
Sea level  
5. Environment:  
6. Radiation:  
Clean, dust-free and non-explosive  
None  
7. Vibration:  
Minimal, i.e. machine mounting  
8. Allowable voltage fluctuation:  
9. Allowable frequency fluctuation:  
+/- 10%  
Continuous  
Intermittent  
+/- 1%  
+/- 2%  
10. Nominal supply voltage:  
460/3/60 (Verify on serial number tag)  
11. Earth ground type: TN (system has one point directly earthed through a protective conductor)  
12. Power supply should include a ground connection.  
13. Over-current protection is supplied in the additive feeder, but additional protection  
should be supplied by the user.  
14. The door-mounted disconnect serves as the electrical disconnect device.  
15. Additive feeder is not equipped with local lighting.  
Additive Feeders  
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16. Functional identification  
17. Additive Feeder is equipped with a CE mark  
18. Additive Feeder is supplied with an operating manual in the language of the  
destination country.  
19. Cable support may be required for power cord, depending on final installation.  
20. 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.  
21. Doors can be opened with a screwdriver, but no keys are required.  
22. Two-hand control is not required or provided.  
23. All additive feeders should be moved around and set in a place with a lift truck or  
equivalent.  
24. There are no frequent repetitive cycles that require manual controlrepetitive  
functions are automatic while the additive feeder is operating.  
25. An inspection report detailing the functional test is included with the additive feeder.  
26. The machine is not equipped with cableless controls.  
27. Color-coded (harmonized) power cord is sufficient for proper installation.  
7-4 Drawings and Diagrams  
Figure 6: Additive Feeder Specifications and Overall Dimensions  
Additive Feeders  
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CONTROLS  
MOUNTING FLANGE  
I
I
SET POINT  
4"  
7"  
SET POINT  
91  
2
9
"
1
"
2
POWER  
MOTOR  
ON  
MOTOR ON  
AUTO  
OFF  
POWER  
MOTOR  
OFF  
MAN  
ON  
MOTOR ON  
AUTO  
OFF  
OFF  
MAN  
4"  
7"  
61  
"
4
61  
"
4
STANDARD  
STANDARD  
WITH OPTIONS  
27 3  
"
4
12"  
183  
4
"
6"  
1
"
4
31  
Additive Feeder  
Type  
Hopper capacity  
Electrical supply  
Amp  
draw  
Shipping weight  
1 Component  
2 Component  
1.0 Cu. Ft.  
(2) 1.0 Cu. Ft.  
115-1-60  
115-1-60  
1.3  
2.5  
50 lbs.  
90 lbs.  
Figure 7: Typical Additive Feeder Controllers  
Additive Feeders  
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SET POINT  
SET POINT  
POWER  
MOTOR  
ON  
MOTOR ON  
POWER  
MOTOR  
OFF  
ON  
MOTOR ON  
AUTO  
OFF  
OFF  
MAN  
SET POINT  
# 1  
SET POINT  
# 1  
(HIGH LEVEL)  
SET POINT  
(HIGH LEVEL)  
SET POINT  
# 2  
SET POINT  
SET POINT # 1  
SET POINT # 1  
(LOW LEVEL)  
MOTOR ON  
SET POINT  
# 2  
SET POINT  
(LOW LEVEL)  
SET POINT  
POWER  
ON  
SET POINT # 2  
SET POINT # 2  
OFF  
POWER  
MOTOR  
MOTOR  
SET POINT # 1  
SET POINT # 2  
MOTOR ON  
ON  
AUTO  
OFF  
AUTO  
OFF  
OFF  
MAN  
MAN  
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7-5 Spare Parts List  
Figure 8: Exploded Assembly Drawing  
Figure 9: Parts List  
Detail # Part number  
Part/assembly description  
Supply Hopper, 1.0 Cubic Foot  
Supply Hopper, 2.0 Cubic Foot  
1
1
A0541207  
A0541208  
A0541225  
A0541226  
A0541227  
A0541286  
A0541285  
A0101190  
A0541206  
W0012471  
2
2
2
3
Hopper Cover, Manual Fill  
Hopper Cover with Cutout for .1 Cubic Foot Hopper Loader  
Hopper Cover with Cutout for .25 Cubic Foot Hopper Loader  
Magnetic Stripping for Supply Hopper Cover  
Screw, ¼-20 x ½", HHC, Grade 5  
Lock Washer, ¼"  
4
5
6
7
Supply Hopper Sight Glass  
Blind Rivet, 3/16"  
8
W00052210 Plunger Pin, Retractable  
9
A0541201  
A0541202  
A0541208  
A0541205  
A0069242  
Material Transfer Tube  
10  
10  
11  
12  
13  
14  
15  
16  
17  
18  
Main Throat, Standard, 6"  
Main Throat, Optional Expanded, 8"  
Main Throat Sight Glass  
Flat Washer, 5/16  
W00001948 Screw, 3/8-16 x ½"  
A0069203  
A0069458  
A0541216  
A0541215  
A0540904  
Lock Washer, 3/8"  
Screw, 3/8-16 x 3/4"  
Calibration Sample Port Plate  
Clean Out Port Plate  
Screw, 10-32 x ½"  
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Detail # Part number  
Part/assembly description  
19  
20  
21  
W00052550 Knob, Knurled  
A0069218  
A0069549  
A0541279  
Stop Nut, 5/16-18  
Flat Washer, 3/8"  
Screw, 5/16-18 x 4½"  
22  
23  
A0069241 Flat Washer, ¼"  
24  
25  
25  
25  
A0541277 Quick Release Pin  
A0541209 Feed Tube Insert, 1/2"  
A0541210 Feed Tube Insert, 3/4"  
A0541211 Feed Tube Insert, 1"  
25  
25  
25  
26  
A0541212 Feed Tube Insert, 1 1/4"  
A0541213 Feed Tube Insert, 1 1/2"  
A0541214 Feed Tube Insert, 1 3/4"  
A0541219 Auger, 1/2"  
26  
A0541220 Auger, 3/4"  
26  
A0541219 Auger, 1"  
26  
A0541292 Auger, 1 1/4"  
Assy.  
Assy.  
Assy.  
Assy.  
Assy.  
Assy.  
27  
A0541292 Auger Assembly, 1/2" *  
A0541293 Auger Assembly, 3/4" *  
A0541294 Auger Assembly, 1" *  
A0541295 Auger Assembly, 1 1/4" *  
A0541296 Auger Assembly, 1 1/2"  
A0541297 Auger Assembly, 1 3/4"  
W00015504 Roll Pin  
28  
A0541284 O Ring  
29  
A0541217 Thrust Bearing  
30  
A0541283 Compression Spring  
31  
W00000947 Lock Washer, #10  
32  
33  
A0103129 Terminal Ring for Retaining Cable  
W00013647 Pin Retaining Cable  
34  
A0541229 Motor Mount  
35  
A0541282 Jaw Coupler  
36  
36  
36  
37  
A0555661 Motor Assy, 115 VAC, 1/10 H.P.  
A0541298 Motor Assembly, 115 VAC 1/20 H.P.  
A0547487 Motor Assembly, 115 VAC, Low RPM 1/20 H.P.  
A0541265 Control, 115 VAC  
37  
37  
37  
37  
37  
38  
39  
A0541266 Control, 115 VAC, Timer/Cycle Counter  
A0541267 Control, 115 VAC, Timer/Elapsed Timer  
A0541268 Control, 115 VAC, Extruder Tracking  
A0541269 Control, 115 VAC, Extruder Tracking, Timer/Elapsed Timer  
A0544795 230 VAC/115 VAC Transformer Control Assembly  
A0541039 Strain Relief for Control Cable  
A0541262 Lock Nut for Strain Relief  
A0539035 Transition Flange, Feed Throat, 7" to 4" Square  
* Auger assemblies include details 26, 27, 28, 29, 30, & 12. Order the appropriately-sized feed tube  
insert (Detail 25) if needed.  
Additive Feeders  
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Figure 10: One Component Control Enclosure Parts Identification  
20  
OR  
19  
6
41  
11  
5
SET POINT  
18  
16  
17  
4
3
9
7
8
9
POWER  
MOTOR  
ON  
MOTOR ON  
(SEE DETAIL A)  
OFF  
10 OR 52  
2
1
50  
14  
15  
12 13  
TO ENCLOSURE  
ON MOTOR  
FUSE HOLDER  
115V  
POWER  
32  
SET POINT  
A0541236  
DETAIL A  
LEFT SIDE VIEW  
OR  
35  
36 30  
31  
34  
230V OPTION  
50  
1
A0544795  
ASSY,TRANSFORMER,CNTL,230:115  
POWER  
MOTOR  
33  
ON  
MOTOR ON  
AUTO  
OFF  
EXTRUDER TRACKING  
OPTION  
41  
40  
1
1
A0541610  
A0541673  
GRAPHIC, CONTROLLER, PERCENT  
SENSOR, OPTICAL, PICKUP  
OFF  
MAN  
(SEE NOTE #2)  
36  
35  
34  
33  
32  
31  
30  
1
1
1
1
1
1
1
A0541238  
A0541276  
W00014736  
A0541234  
A0541252  
A0541261  
A0541259  
TIMER, SOCKET, 11 PIN  
COUNTER, ELAPSE TIME, LCD  
SW, TOGGLE, DPDT, 0N-OFF-ON  
GRAPHIC, TMR/CNT  
ENCLOSURE, 8 x 6 x 6, TMR/CNT  
COUNTER, CYCLE, LCD, TOTALIZER  
TIMER, LCD, PRESET  
TIMER/CYCLE COUNTER OR  
TIMER/ELAPSE TIME COUNTER  
OPTION  
(SEE DETAIL B)  
DETAIL B  
TIMER/CYCLE COUNTER OR  
TIMER/ELAPSE TIME COUNTER  
20  
19  
2
1
A0541613  
A0541235  
A0541258  
A0541262  
A0541039  
A0536541  
W00012591  
A0541611  
A0803495  
A0541233  
A0536646  
W00014276  
A0541257  
W00002540  
A0541244  
W00020484  
A0534272  
A0503765  
A0541253  
A0541251  
SCRW,ROUND HD,6-32,1/2" LG,BLK  
GRAPHIC, CONTROLLER  
CABLE, 6 COND, SHIELD  
NUT, LOCK, STRIAN RELIEF, 3/4"  
STRAIN RELIEF, 3/4"  
STRAIN RELIEF, PIGTAIL  
CORD, SET, W/PLUG, 9', 115V ONLY  
FUSE, 250V, MDL, 3/4 AMP  
FUSE, HOLDER  
18 10ft  
17  
16  
15  
14  
13  
12  
11  
10  
9
8
7
6
5
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
GRAPHIC, STANDARD  
LIGHT, GREEN, NEON  
BOOT, RUBBER, TOGGLE SWITCH  
SW, TOGGLE, DPDT, ON-OFF-MOM  
SW, TOGGLE, SPST  
CONTROLLER, SPEED, STANDARD  
TERMINAL STRIP, 6 POSITION  
SOCKET, RELAY  
RELAY, DPDT  
PANEL, SUB, 8 x 6  
ENCLOSURE, 8 x 6 x 6, STANDARD  
DESCRIPTION  
NOTE:  
1) OPTIONAL ITEMS ARE SHOWN WITH A DASHED  
BOX.  
2) ITEM #40 (NOT SHOWN ON DRAWING) TO BE  
FIELD INSTALLED.  
4
3
2
1
ITEM QTY PART NUMBER  
STANDARD BILL OF MATERIAL  
Additive Feeders  
Chapter 7: Appendix  
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Figure 11: Two Component Control Enclosure Parts Identification  
SET POINT  
# 1  
20  
10  
(HIGH LEVEL)  
SET POINT  
SET POINT # 1  
41 OR 19  
6
5
17  
SET POINT  
# 2  
3
4
4
18  
21  
16  
10  
8
11  
(LOW LEVEL)  
SET POINT  
SET POINT # 2  
3
2
OR 37 38  
9
7
1
9
POWER  
MOTOR  
MOTOR ON  
ON  
AUTO  
OFF  
SEE DETAIL A  
OFF  
MAN  
10  
50  
15  
14  
TO ENCLOSURE  
ON MOTOR  
12 13  
PROX SWITCH  
(ITEM #22)  
FUSE HOLDER  
115V  
POWER  
SET POINT  
# 1  
(HIGH LEVEL)  
33  
A0541237  
SET POINT  
SET POINT  
# 2  
SET POINT # 1  
(LOW LEVEL)  
MOTOR ON  
DETAIL A  
LEFT SIDE VIEW  
32  
50  
1
A0544795  
ASSEMBLY,TRANSFORMER,CNTL,230:115  
230V OPTION  
SET POINT  
POWER  
ON  
SET POINT # 2  
41  
40  
2
2
A0541610  
A0541673  
GRAPHIC, CONTROLLER, PERCENT  
SENSOR,OPTICAL,PICKUP  
EXTRUDER TRACKING  
OPTION  
OFF  
(SEE #2)  
34  
MOTOR  
35 OR 31  
SET POINT # 1  
SET POINT # 2  
38  
37  
36  
35  
34  
33  
32  
31  
30  
1
1
1
2
1
1
1
2
1
A0505418  
A0505417  
A0541238  
A0541276  
W00014736  
A0541264  
A0541255  
A0541261  
A0541259  
RELAY, SOCKET  
RELAY, 4PDT  
TIMER, SOCKET, 11 PIN  
COUNTER, ELAPSE TIME, LCD  
SW, TOGGLE, DPDT, 0N-OFF-ON  
GRAPHIC, TMR/CNT  
ENCLOSURE, 10 x 8 x 6, TMR/CNT  
COUNTER, CYCLE, LCD, TOTALIZER  
TIMER, LCD, PRESET  
30 OR 36  
TIMER/CYCLE COUNTER OR  
TIMER/ELAPSE TIME COUNTER  
OPTION  
(SEE DETAIL B)  
DETAIL B  
TIMER/CYCLE COUNTER OR  
TIMER/ELAPSE TIME COUNTER  
22  
21  
20  
19  
1
1
4
2
A0536225  
A0536549  
A0541613  
A0541235  
A0541258  
A0541262  
A0541039  
A0536541  
W00012591  
A0541611  
A0803495  
A0541263  
A0536646  
W00014276  
A0541257  
W00002540  
A0541244  
W00020484  
A0534272  
A0503765  
A0541256  
A0541254  
SW,PROX,NO,CAP,18MM,CAO010VCSN  
STRF,HEYCO,18-2,1150  
SCRW,ROUND HD,6-32,1/2" LG,BLK  
GRAPHIC, CONTROLLER  
CABLE, 6 COND, SHIELD  
NUT, LOCK, STRAIN RELIEF, 3/4"  
STRAIN RELIEF, 3/4"  
STRAIN RELIEF, PIGTAIL  
CORD, SET, W/PLUG, 9', 115V ONLY  
FUSE, 250V, MDL, 3/4 AMP  
FUSE, HOLDER  
GRAPHIC, DUAL SET POINT  
LIGHT, GREEN, NEON  
BOOT, RUBBER, TOGGLE SWITCH  
SW, TOGGLE, DPDT, ON-OFF-MOM  
SW, TOGGLE, SPST  
18 10ft  
17  
16  
15  
14  
13  
12  
11  
10  
9
8
7
6
5
1
1
1
1
1
1
1
3
2
1
1
2
1
2
2
1
1
NOTE:  
1) OPTIONAL ITEMS ARE SHOWN WITH A DASHED  
BOX.  
CONTROLLER, SPEED, STANDARD  
TERMINAL STRIP, 6 POSITION  
SOCKET, RELAY  
RELAY, DPDT  
PANEL, SUB, 10 x 8  
2) ITEM #40 (NOT SHOWN ON DRAWING) TO BE  
FIELD INSTALLED.  
4
3
2
1
ENCLOSURE, 10 x 8 x 6  
ITEM QTY PART NUMBER  
DESCRIPTION  
STANDARD BILL OF MATERIAL  
Additive Feeders  
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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 15% ($75.00  
minimum) restocking charge.  
ALL returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period  
and/or in new and unused condition, suitable for resale.  
Warranty Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A  
RMA number will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s  
discretion. If the item is found to be defective in materials or workmanship, and it was  
manufactured by our company, purchased components are covered under their specific  
warranty terms.  
7-7 Safety Tag Information  
Additive Feeder Safety Tags  
Read Operation  
and Installation  
Manual  
Shear Hazard  
Rotating Auger  
High Voltage  
Earth Ground  
Inside Enclosure  
PE Protected Earth  
Ground  
Lifting Point  
Additive Feeders  
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7-8 Additive Feeder Identification (Serial Number) Tag  
(Located on back of Additive Feeder)  
Company Logo  
XX-X Series Additive Feeder  
Model Number XX-X  
Max Blend Capacity 318 KG/HR  
220V  
1Ǿ  
Serial Number 060701R  
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 lbs/(180 KG)  
Electrical Diagrams &  
Pneumatic Diagram  
Street Address  
City, State Zip Code  
Telephone Number  
7-9 Technical Assistance  
Parts Department  
[
]
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call 630 595-1060, Fax [630] 475-7005  
The ACS Customer Service Group will provide your company with genuine OEM quality parts  
manufactured to engineering design specifications, which will maximize your equipment’s performance  
and efficiency. To assist in expediting your phone or fax order, please have the model and serial  
number of your unit when you contact us. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
[
]
[
]
Call toll-free 8am–5pm CST 800 233-4819 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  
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Worksheet for Charting Feed Rates  
Material ________________________________  
Auger size _______________________________  
Feed rate unit of measure _________________  
Trial #1 rpm _____________ Feed rate _______________  
Trial #2 rpm _____________ Feed rate _______________  
80  
70  
60  
Auger 50  
RPM  
40  
setting  
30  
20  
10  
0
____ ____ ____ ____ ____ ____ ____ ____  
0
Observed feed rates (lbs./hr., oz./min., etc.)  
- Photocopy this page for your records -  
Additive Feeders  
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