Sterling Wheelchair AF XXX User Manual

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