Sterling AF-XXX - Manuals

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 and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and an...

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 instructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the m...

Additive Feeders Chapter 1: Safety viii 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 forg...

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...

Additive Feeders Chapter 1: Safety x 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...

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 maintenance instructions for 1 and 2 component additive feeders. Model numbers are listed on the serial tag. Make sure you...

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. • Hal...

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 speed changes. Quick Change Supply Hopper • 0.3 cubic foot capacity hopper with slide ga...

Additive Feeders Chapter 3: Installation 15 of 55 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 carefu...

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 na...

Additive Feeders Chapter 3: Installation 17 of 55 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 carr...

Additive Feeders Chapter 3: Installation 18 of 55 Figure 1: Conversion Chart Multiply By To obtain Ounces per Second 225 Pounds per 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...

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 au...

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 ca...

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 t...

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 examples. If you are unfamiliar with this product or have never perform...

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 examples. If you are unfamiliar with this product or have never performed this ...

Additive Feeders Chapter 4: Operation 29 of 55 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 ac...

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 user to configure a number of adjustable parameters. The LED display has three basic o...

Additive Feeders Chapter 4: Operation 32 of 55 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 ...

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 pulse per revolution generates 15 pulses per minute...

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-Selection Mode, the unit will return to Running Mode and display the running valu...

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...

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 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...

Additive Feeders Chapter 6: Maintenance 39 of 55 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 inter...

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/...

Additive Feeders Chapter 6: Maintenance 41 of 55 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 ...

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 Additiv...

Additive Feeders Chapter 7: Troubleshooting 43 of 55 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, l...

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 equipment that could alter the CE compliance 2. Ambient temperature: 0 degrees C...

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 AUT...

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 Hopper, 1.0 Cubic Foot 1 A0541208 Supply Hopper, 2.0 Cubic Foot 2 A0541225 Hopper Cover, Manual Fill 2 A0541226...

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 ...

Additive Feeders Chapter 8: Appendix 52 of 55 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 ...

Additive Feeders Chapter 8: Appendix 53 of 55 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 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 will provide your company with genuine OEM quality parts manufactured to engineering design spec...

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 _...