Instruction/ maintenance manual of the product AF-XXX Sterling
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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: _________________________ ___________________.
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.
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 .
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 O.
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 .
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 Scr.
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 T.
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.
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.
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 Ser.
Additive Feeders Chapter 8: Appendix 55 of 55 Worksheet for Charting Feed Rates Material ________________________________ Auger size _______________________________ Feed rate unit of measure _________.
An important point after buying a device Sterling AF-XXX (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling AF-XXX yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling AF-XXX - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling AF-XXX you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling AF-XXX will certainly help you make a decision on the purchase.
If you already are a holder of Sterling AF-XXX, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling AF-XXX.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling AF-XXX. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling AF-XXX along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
