Sterling 882.00274.00 manual

SF Series Additive Feeders Part Number: 882.00274.0 0 Bulletin Number: BF2-605 Effective: 10/31/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing prog[...]

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Additive Feeders ii Shipping Information Unpacking and Inspection You should inspect your additive feeder for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc. In the Event of Shipping Damage Accordin[...]

Additive Feeders iii Table of Contents CHAPTER 1: SAFETY ................................................................. V 1-1 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual ...................................................................[...]

Additive Feeders iv CHAPTER 5: MAINTENANCE ................................................... 32 5-1 Preventative Maintenance Schedule ......................................................................... 32 5-2 Preventative Maintenance ......................................................................................... 33 Material Cleano[...]

Additive Feeders Chapter 1: Safety v of 50 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 main ten[...]

Additive Feeders Chapter 1: Safety vi 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulat[...]

Additive Feeders Chapter 1: Safety vii 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with its operation[...]

Additive Feeders Chapter 1: Safety viii Operator Responsibility The operator’s responsibility does not end with e fficient 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[...]

Additive Feeders Chapter 1: Safety ix • Clean the feeder and surrounding area DAILY , and inspect the machine for loose, missing or broken parts. • Shut off power to the feeder when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If [...]

Additive Feeders Chapter 2: Functional Description 10 of 50 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance 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 equipme[...]

Additive Feeders Chapter 2: Functional Description 11 of 50 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 micropr[...]

Additive Feeders Chapter 2: Functional Description 12 of 50 Dual Setpoint Control • Used with multiple feeder installations wher e one feeder is feeding colored regrind and another is feeding straight color. A low level monitor senses when the supply of colored regrind is depleted and alters the feed rate of the pure color feeder to maintain prec[...]

Additive Feeders Chapter 2: Functional Description 13 of 50 2-6 Safety Device s 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 ma terial contained in [...]

Additive Feeders Chapter 2: Functional Description 14 of 50 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. T he safety devices that are used on these additive feeders are primarily c oncerned with electrical power disconnection and the disabling of moving parts that may n eed to be accessed during the norma[...]

Additive Feeders Chapter 3: Installation 15 of 50 Chapter 3: Inst allation 3-1 Uncrating the Equipment Additive feeders are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding sta[...]

Additive Feeders Chapter 3: Installation 16 of 50 3-3 Electrical Connections When making electrical connections to your additive feeder, ensure that you take into consideration and make arrangements for the following: • A qualified electrician should make all electrical connections. • Fulfill all national, state, and local safety and electrical[...]

Additive Feeders Chapter 3: Installation 17 of 50 3-4 Setup Procedures This section provides the procedures necessar y for configuring your additive feeder. Configuration of your additive feeder includ es determining the desired feed rate and calibrating the additive feeder. We recomme nd that you carry out these procedures in the order given here.[...]

Additive Feeders Chapter 3: Installation 18 of 50 Figure 1: Conversion Chart Multiply By To obtain Ounces per Second 225 Pounds pe r Hour Grams 0.035 Ounces Ounces 0.0625 Pounds Seconds 0.00028 Hours Figure 2: Rate Chart 0 10 20 30 40 50 60 70 80 90 100 110 1/2 lb/hr 1 1/2 lb/hr 7 lb/hr 25 lb/hr 4 lb/hr 55 lb/hr 7 lb/hr 110 lb/hr 1/2" auger 3/[...]

Additive Feeders Chapter 3: Installation 19 of 50 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 ha[...]

Additive Feeders Chapter 3: Installation 20 of 50 Examples: This example shows how to extrapolate a desire d feed rate of 3 lbs./hr., based on the feed rates of 3 trial rpm settings. Observed Feed Rates Sample 1 = 2 pounds per h our @ 20 rpm Sample 2 = 4 pounds per h our @ 40 rpm Sample 3 = 6 pounds per h our @ 60 rpm In this example, a feed rate o[...]

Additive Feeders Chapter 3: Installation 21 of 50 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 tool[...]

Additive Feeders Chapter 4: Operation 22 of 50 Chapter 4: Operation 4-1 Start-up 1. Turn the power switch ON . 2. Set the desired feed rate on the RPM display using the up or down arrows. 3. Flip the motor switch to AUTO . If the additive feeder is installed correcly, it should begin operation at the desired RPM when the processing machine screw is[...]

Additive Feeders Chapter 4: Operation 23 of 50 Timer/Counter Control Operation (Injection Molding Applications) The Timer/Counter control is designed for use with cyclical processes like injection molding and features a timer and counter module. It also acts as a cycle override safety timer. Timer Module This feature of the controller assists in ca[...]

Additive Feeders Chapter 4: Operation 24 of 50 Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications) The Timer/Elapsed Timer control is desi gned for use with continuous processes like extrusion and blow molding and features a timer and elapsed tim e module. Timer Module This feature of the controller assists in calib ration of th[...]

Additive Feeders Chapter 4: Operation 25 of 50 Dual Setpoint Control Operation (2 Component Applications) A dual setpoint control operation is offered on the dual auger/hopper additive feeder. Typically, one feeder hopper is filled with additiv e and the other (with a proximity switch) is filled with regrind. This option allows for the accurate add[...]

Additive Feeders Chapter 4: Operation 26 of 50 Extruder Tracking Control The extruder tracking control option allows the a dditive feeder’s auger (follower) to turn in a precise ratio to the speed of your extruder screw (master). The speed control on the feeder can be set for any feed ratio from 1% to 999.9%. The extruder tracking control detects[...]

Additive Feeders Chapter 4: Operation 27 of 50 6. Determine the desired additive feeder setpoint (% of extruder (master) screw RPM). To determine this, you must know: • Total extruder feedrate (lbs./hr.). • The RPM of the extruder screw at that feedrate. • The letdown ratio of the additive (% or :). • The additive feedrate required at that [...]

Additive Feeders Chapter 4: Operation 28 of 50 Field Control Programming The standard additive feeder controller has the ab ility to display feed rates in units other than the factory set auger RPM display. With th e proper programming, the feeder can display pounds/hour, grams/m inute, etc. The non-volatile mem ory retains the program if the power[...]

Additive Feeders Chapter 4: Operation 29 of 50 Programming Mode The motor will stop when in Programming m ode. 1. Make sure DIP switches 1 through 4 and 7 and 8 are OFF . 2. Flip switch 7 to ON . 3. The display should read PROG . 4. Follow the instructions given below to vi ew and/or edit any of the variables. Viewing or Changing Displayed Decimal [...]

Additive Feeders Chapter 4: Operation 30 of 50 Viewing or Changing the Program Minimum Setting 1. Enter the programming mode, then flip DIP switch 2, Program Minimum Setting, to ON . 2. The current value for the lower limit FACTORY SETTING = 0 will appear in the LED display. 3. Use the Up or Down buttons to change the lower limit, as desired. 4. Wh[...]

Additive Feeders Chapter 4: Operation 31 of 50 Additive Feeder Control Factory Defaults WARNING! This procedure involves resetting a DIP switch within a live electrical enclosure. Only persons with the proper knowledge of and respect for working on energized electrical devices should attempt this procedure. Use extreme caution! Note: Set the decima[...]

Additive Feeders Chapter 5: Maintenance 32 of 50 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The checklist below contains a list of items wh ich should be inspected and/or replaced to keep your Additive Feeder operating at peak e fficiency. Perform each inspection at the regular intervals listed below. System model # Serial # Every[...]

Additive Feeders Chapter 5: Maintenance 33 of 50 5-2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your additive feeder. Perform them at the regular intervals listed on the checklist on the previous page. Material Cleanout/Changeover Caution! Never put hands or tools in or[...]

Additive Feeders Chapter 5: Maintenance 34 of 50 5-3 Corrective Maintenance This section provides you with the informati on necessary to correct or repair any issues which might appear during the norma l operation of your additive feeder. Although we have listed how to perform these procedures, it is recommended that you call the Service Department[...]

Additive Feeders Chapter 5: Maintenance 35 of 50 Motor Brush Replacement The two (2) motor brushes should be replaced when they are worn down to less than 1 inch in length. Replacement brushes are “pre-worn” by the manufacturer and require no break-in period. Caution! Disconnect power to the Additive F eeder before changing the motor brushes. 1[...]

Additive Feeders Chapter 6: Troubleshooting 36 of 50 Chapter 6: T roubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting m ust be accomplished with the power off, line fuses rem oved, and with the machine tagged[...]

Additive Feeders Chapter 6: Troubleshooting 37 of 50 Problem Possible cause Corrective action Field contact jumper (J1) has not been removed. AUTO MODE. Remove jumper and wire the terminals to the processing machine relay. Field contact to the processing machine has failed. Check wiring/check the relay on the processor. Motor switch has failed. Rep[...]

Additive Feeders Chapter 7: Appendix 38 of 50 Chapter 7: Appendix 7-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used un der recommended conditions. The company’s obligation is limited to repair or replace FOB th e factory any parts that are returned prepaid within [...]

Additive Feeders Chapter 7: Appendix 39 of 50 7-2 Optional Components The following is a list of options which your Additive Feeder may have been equipped with: Special Voltage • 230/1/50 VAC Timer/Counter Control • Designed for use with cycled processes like injection molding • Cycle timer can be set to limit additive feeder cycle to avoid f[...]

Additive Feeders Chapter 7: Appendix 40 of 50 7-3 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equi pment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% re[...]

Additive Feeders Chapter 7: Appendix 41 of 50 16. Functional identification 17. Additive Feeder is equipped with a CE mark 18. Additive Feeder is supplied with an op erating manual in the language of the destination country. 19. Cable support may be required for power co rd, depending on final installation. 20. No one is required to be in the inter[...]

Additive Feeders Chapter 7: Appendix 42 of 50 " 1 6 4 " 9 2 1 MOTOR OFF ON POWER MOTOR ON MAN AUTO OFF ADDITIVE FEEDER SET POINT " 1 9 2 6 4 " 1 MOTOR POWER OFF ON MOTOR ON SET POINT MAN OFF AUTO 7" 4" 4" 7" 3 " 18 4 31 " 1 4 27 4 3 " 12" 6" MOUNTING FLANGE CONTROLS STANDARD STANDARD [...]

Additive Feeders Chapter 7: Appendix 43 of 50 ON OFF MOTOR ON POWER MOTOR SET POINT SET POINT MOTOR AUTO OFF MAN MOTOR ON POWER ON OFF SET POINT # 2 SET POINT # 1 SET POINT SET POINT MOTOR POWER MOTOR ON OFF ON MAN AUTO OFF # 1 SET POINT SET POINT # 2 (HIGH LEVEL) (LOW LEVEL) SET POINT SET POINT SET POINT # 1 SET POINT # 2 SET POINT # 1 SET POINT #[...]

Additive Feeders Chapter 7: Appendix 44 of 50 7-5 Spare Parts List Figure 8: Exploded Assembly Drawing Figure 9: Parts List Detail # Part number Part/assembly description 1 A0541 207 Supply Hopper, 1.0 Cu bic Foot 1 A0541 208 Supply Hopper, 2.0 Cu bic Foot 2 A0541 225 Hopper Cover, Manual Fill 2 A0541 226 Hopper Cover with Cutout for .1 Cubi c Foot[...]

Additive Feeders Chapter 7: Appendix 45 of 50 Detail # Part number Part/assembly description 19 W00052550 Knob, Knurled 20 A0069218 Stop Nut, 5/16-18 21 A0069549 Flat Washer, 3/8" 22 A0541279 Screw, 5/16-18 x 4½" 23 A0069241 Flat Washer, ¼" 24 A0541277 Quick Release Pin 25 A0541209 Feed Tube Insert, 1/2" 25 A0541210 Feed Tube [...]

Additive Feeders Chapter 7: Appendix 46 of 50 Figure 10: One Component Control Enclosure Parts Identification Whitlock R ON OFF MOTOR ON POWER MOTOR SET POINT ADDITIVE FEEDER 6 10 8 11 7 9 9 DETAIL B TIMER/CYCLE COUNTER OR TIMER/ELAPSE TIME COUNTER 19 1 30 ADDITIVE FEEDER SET POINT MOTOR POWER MOTOR ON OFF ON R Whitlock MAN AUTO OFF 32 31 35 OR 34 [...]

Additive Feeders Chapter 7: Appendix 47 of 50 Figure 11: Two Component Control Enclosure Parts Identification SET POINT # 2 SET POINT # 1 SET POINT ADDITIVE FEEDER SET POINT MOTOR POWER MOTOR ON OFF ON R Whitlock MAN AUTO OFF 2 4 115V SEE DETAIL A 14 15 12 18 16 17 5 13 6 8 10 9 11 19 7 1 9 34 33 32 31 30 35 OR DETAIL B TIMER/CYCLE COUNTER OR TIMER[...]

Additive Feeders Chapter 7: Appendix 48 of 50 7-6 Returned Material Policy Credit Returns Prior to the return of any material authorization m ust 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[...]

Additive Feeders Chapter 7: Appendix 49 of 50 7-8 Additive Feeder Identifi cation (Serial Number) Tag (Located on back of Additive Feeder) Company Logo XX-X Series Additive Feeder Model Number XX-X Max Blend Capacity 318 KG/HR 220V Serial Number 060701R 1 Ǿ Date of Manufacture 06/2004 4.5A Over-current Protec tion Device (s) 4.5A Total Frequency 5[...]

Additive Feeders Chapter 7: Appendix 50 of 50 Worksheet for Charting Feed Rates Material ________________________________ Auger size _______________________________ Feed rate unit of measure _________________ Trial #1 rpm _____________ Feed rate _______________ Trial #2 rpm _____________ Feed rate _______________ 0 10 20 30 40 50 60 70 0 ____ ____ [...]