Sterling AF-XXX 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 pro[...]

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 Resetting the Unit to Un-Programmed State ....................................................... 25 JP1 (Program Enable Jumper) ............................................................................ 25 Programming Step by Step Guide ....................................................................... 25 Injection Mode [...]

Additive Feeders Chapter 1: Safety v of 55 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. Additive Feeder Safety Tags Read Operation Shear Hazard and Installation [...]

Additive Feeders Chapter 1: Safety x When you have completed the repair or mainte nance 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 N OT start and run the machine until you are sure all parts are functioning correctly. BEFORE you[...]

Additive Feeders Chapter 2: Functional Description 11 of 55 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 12 of 55 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 13 of 55 Extruder Following Feature • This feature allows the additive feeder to automatically increase or decrease the material feed rate as the extruder screw sp eed changes. Quick Change Supply Hopper • 0.3 cubic foot capacity hopper with slide ga te allows for rapid change of additives Supp[...]

Additive Feeders Chapter 2: Functional Description 14 of 55 Safety Circuit Standards Safety circuits used in industrial systems protect the o perator 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 establis hment of sa[...]

Additive Feeders Chapter 3: Installation 15 of 55 Chapter 3: Inst allation 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 lif t the box off carefully; avoiding staples in the 1’ x 4’ wood su[...]

Additive Feeders Chapter 3: Installation 16 of 55 3-3 Electrical Connections When making electrical connections to your additive feeder, ensure that you take into consideration and make arrangements for the following: • A qualified electrician should make all electrical connections. • Fulfill all national, state, and local safety and electrical[...]

Additive Feeders Chapter 3: Installation 17 of 55 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 55 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 55 Calibration Procedure This procedure allows the operator to precisely adjust additive feed rates. Caution! Never put hands or tools in or near the auger assembly when power is connected. Do not wear gloves or loose clothing during calibration. The auger is exposed when the calibration or cleanout ha[...]

Additive Feeders Chapter 3: Installation 20 of 55 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 55 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 55 Chapter 4: Operation 4-1 Start-up 1. Turn the power switch ON . 2. Set the desired feed rate on the RPM display using the up or down arrows. 3. Flip the motor switch to AUTO . If the additive feeder is installed correctly, it should begin operation at the desired RPM when the processing machine screw i[...]

Additive Feeders Chapter 4: Operation 23 of 55 Procedure 1. Time the duration of feeder operation during a typical Injection molding machine shot cycle. 2. Set the timer to a slightly longer value. 3. Start the additive feeder by flipping the motor switch to the AUTO position. 4. If the timer times out because of a process flow problem, the feeder [...]

Additive Feeders Chapter 4: Operation 24 of 55 4-3 Injection Molding Applications Discussed in this portion of the manual are the finer points of the additive feeder operation, programming the control, and installation notes and e xamples. If you are unfamiliar with this product or have never performed this type of installation, please read this se[...]

Additive Feeders Chapter 4: Operation 25 of 55 editing purposes. Pressing the Up or Down button will increase or decrease the selected parameter number on the display. Although the parameter numbers are in numerical order, some numbers are skipped. These numbers represent reserved parameters that are not y et implemented and are not displayed. Once[...]

Additive Feeders Chapter 4: Operation 26 of 55 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 M[...]

Additive Feeders Chapter 4: Operation 27 of 55 feeder. If you do not have these drawings contact service to have them forwarded to you. Injection Mode Application Notes The additive feeder controller h as the ability to display feed rates in units other than the factory set auger RPM display. With proper programming, the feeder can display pounds/h[...]

Additive Feeders Chapter 4: Operation 28 of 55 4-4 Extrusion Applications Discussed in this portion of the manual are the finer points of the additive feeder operation, programming the control, and installation notes and e xamples. If you are unfamiliar with this product or have never performed this type of installation, please read this section of[...]

Additive Feeders Chapter 4: Operation 29 of 55 Extruder Tracking Installation and Setup The additive feeder control is supplied with st andard factory defaults. Control pr ogramming 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 senso[...]

Additive Feeders Chapter 4: Operation 30 of 55 Field Control Programming Although the drive’s user interface is very versatile, it is also simple to setup and operate. With just a few button presses, it allows the u ser to configure a number of adjustable parameters. The LED display has three basi c operating modes: Running Mode, Parameter- Selec[...]

Additive Feeders Chapter 4: Operation 31 of 55 Resetting the Unit to Un-Programmed State The factory-default settings can be easily rest ored using either of two methods. Both methods require the Program Enable jumper to be in the “On” position. The first is to appl y power to the unit with both the Enter and Down buttons pressed for 3 seconds.[...]

Additive Feeders Chapter 4: Operation 32 of 55 14. Use the Up and Down Arrow buttons to go to the nex t 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. Remov[...]

Additive Feeders Chapter 4: Operation 33 of 55 Example 1: An extruder rotating at 30 RPM and providing 8 pulses per revolution generates 240 pulses per minute will provide excellent results. Example 2: An extruder rotating at 15 RPM and providing 1 p ulse per revolution generates 15 pulses per minute and will provide poor results. Maximum Input Pul[...]

Additive Feeders Chapter 5: Program Parameter Descriptions 34 of 55 Chapter 5: Program Parameter Descriptions 5-1 Defining Program Parameters Parameter 0 – Exit to Running Mode When parameter 0 is selected in Parameter-Sel ection Mode, the uni t will return to Running Mode and display the running value. Thi s shoul d be selected once changes to p[...]

Additive Feeders Chapter 5: Program Parameter Descriptions 35 of 55 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 requ ested direction until either the Display Minimum or Display Maximum is reached. The displayed value will initially s[...]

Additive Feeders Chapter 5: Program Parameter Descriptions 36 of 55 Parameter 19 – Power-up Value When Power-up Mode is set to 2, this parame ter will designate the default display value at power-up in display units. Parameter 20 – Display Minimum This parameter defines the lower end of the disp lay range. This is the value which lim its how lo[...]

Additive Feeders Chapter 5: Program Parameter Descriptions 37 of 55 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 n[...]

Additive Feeders Chapter 5: Program Parameter Descriptions 38 of 55 Parameter 36 – Signal Input 2 (S2) Setpoint When the S2 configuration, parameter 35, is set to on e of the jog modes, this parameter defines the jog setpoint in display units. If the drive operating m ode is set to Follower Mode, then this parameter is set in RPM units. This allo[...]

Additive Feeders Chapter 6: Maintenance 39 of 55 Chapter 6: Maintenance 6-1 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 6: Maintenance 40 of 55 6-2 Preventative Maintenance This section describes maintenance procedures which will increase the longevity and efficiency of your additive feeder. Perform them at the regular intervals listed on the checklist on the previous page. Material Cleanout/Changeover Caution! Never put hands or tools in or[...]

Additive Feeders Chapter 6: Maintenance 41 of 55 6-3 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 6: Maintenance 42 of 55 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 7: Troubleshooting 43 of 55 Chapter 7: T roubleshooting 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 m ust be accomplished with the power off, line fuses removed, and with the machine tagged a[...]

Additive Feeders Chapter 7: Troubleshooting 44 of 55 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: Troubleshooting 45 of 55 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 app[...]

Additive Feeders Chapter 8: Appendix 46 of 55 Chapter 8: Appendix 8-1 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this eq uipm ent that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. E[...]

Additive Feeders Chapter 8: Appendix 47 of 55 8-2 Drawings and Diagrams Figure 3: Additive Feeder Specifications and Overall Dimensions " 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 [...]

Additive Feeders Chapter 8: Appendix 48 of 55 Figure 4: Typical Additive Feeder Controllers ON OFF MOTOR ON POWER MOTOR SET POINT SET POINT MOTOR AUTO OFF MAN MOTOR ON POWER ON OFF[...]

Additive Feeders Chapter 8: Appendix 49 of 55 8-3 Spare Parts List Figure 5: Exploded Assembly Drawing Figure 6: Parts List Detail # Part number Part/assembly description 1 A0541207 Supply Hopp er, 1.0 Cu bic Foot 1 A0541208 Supply Hopp er, 2.0 Cu bic Foot 2 A0541225 Hopper Cove r, Manual Fill 2 A0541226 Hoppe r Cove r with Cutout for .1 Cubi c Foo[...]

Additive Feeders Chapter 8: Appendix 50 of 55 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 8: Appendix 51 of 55 Figure 7: 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 3[...]

Additive Feeders Chapter 8: Appendix 52 of 55 8-4 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 8: Appendix 53 of 55 8-6 Additive Feeder Identifi cation (Serial Number) Tag (Located on back of Additive Feeder) COMPANY LOGO Additive Feeder Serial # XXXXXXX Model No. AF-XXX Volt Hz Ph NEMA Motor AMP. Control Circuit Volt[...]

Additive Feeders Chapter 8: Appendix 54 of 55 8-7 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641-8610, Fax [262] 641-8653 The ACS Customer Service Group w ill provide your compa ny with genuine OEM quality parts manufactured to engi neering design specifications, which will maximize your equ[...]

Additive Feeders Chapter 8: Appendix 55 of 55 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 ____ ____ [...]