Page 3 - Shipping Information; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact the shipping department immediately; Hold the items until you receive shipping instructions
Additive Feeders ii Shipping Information Unpacking and Inspection You should inspect your additive feeder for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws...
Page 4 - Table of Contents
Additive Feeders iii Table of Contents CHAPTER 1: SAFETY .................................................................V 1-1 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual .....................
Page 6 - Additive Feeders; -1 How to Use This Manual; Safety Symbols Used in this Manual
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....
Page 7 - -2 Warnings and Precautions
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...
Page 8 - General Responsibility
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...
Page 9 - Operator Responsibility
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...
Page 10 - Maintenance Responsibility; DO NOT; Reporting a Safety Defect
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 ...
Page 11 - Chapter 2: Functional Description; -1 Models Covered in This Manual; Mechanical Features; Transport Tube
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 maintenance instructions for 1 and 2 component additive feeders. Model numbers are listed on the serial tag. Make sure you...
Page 12 - Electrical Features; Motor Assembly; Controller Features; Special Voltage
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. • Hal...
Page 14 - Devices and Interlocks; Safety Circuit Standards
Additive Feeders Chapter 2: Functional Description 13 of 50 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 thi...
Page 16 - Chapter 3: Installation; -1 Uncrating the Equipment; Supply System Installation
Additive Feeders Chapter 3: Installation 15 of 50 Chapter 3: Installation 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 ...
Page 17 - Connections; A qualified electrician should make all electrical connections.; Main Power Connection
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 na...
Page 18 - Procedures; Determining the Desired Feed Rate; Cyclical Processing Equation:; Shot size = 8 ounces; Continuous Processing Equation:; Total throughput = 100 pounds per hour
Additive Feeders Chapter 3: Installation 17 of 50 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...
Page 19 - Figure 1: Conversion Chart; Multiply; Figure 2: Rate Chart
Additive Feeders Chapter 3: Installation 18 of 50 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...
Page 20 - Calibration Procedure; Procedure
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 au...
Page 22 - Starting Up the Additive Feeder; ON; Shutting Down the Additive Feeder; OFF
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 ca...
Page 23 - Chapter 4: Operation; -2 Controller Description and Operation; Switches
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 th...
Page 26 - Regrind Feeder with Proximity Switch
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 additive and the other (with a proximity switch) is filled with...
Page 27 - Extruder Tracking Control; VDC TTL NPN RPM; Extruder Tracking Installation and Setup
Additive Feeders Chapter 4: Operation 26 of 50 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 1% t...
Page 28 - Extruder Tracking Equation:; Total extruder feedrate = 500 pounds per hour
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 :)....
Page 29 - Desired Display Setting; The motor shaft magnet/sensor pulses twice per motor revolution.; Calculating a constant to display pounds per hour:; How the factory pre-set constant was calculated:
Additive Feeders Chapter 4: Operation 28 of 50 Field Control Programming The standard additive feeder controller has the ability to display feed rates in units other than the factory set auger RPM display. With the proper programming, the feeder can display pounds/hour, grams/minute, etc. The non-vo...
Page 30 - PULSES PER REVOLUTION OF FOLLOWER = 30.0
Additive Feeders Chapter 4: Operation 29 of 50 Programming Mode The motor will stop when in Programming mode. 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 view and/or edit any of the v...
Page 31 - BEFORE; Figure 3: DIP Switch Function Table
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 bu...
Page 32 - Figure 4: Additive Feeder Control Factory Defaults; -3 Shutting Down the Additive Feeder
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 pr...
Page 33 - Chapter 5: Maintenance; -1 Preventative Maintenance Schedule; Every week; Every month Jan Feb Mar Apr May Jun; - Photocopy this page for your maintenance records -
Additive Feeders Chapter 5: Maintenance 32 of 50 Chapter 5: Maintenance 5-1 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...
Page 34 - Maintenance; MANUAL
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/...
Page 35 - Auger Assembly Changeover; before; removing an auger; Removing Auger Assembly
Additive Feeders Chapter 5: Maintenance 34 of 50 5-3 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 ...
Page 36 - Motor Brush Replacement; Figure 5: Replacement Motor Brush Part Numbers; Part Number
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 Additiv...
Page 37 - Chapter 6: Troubleshooting; Problem
Additive Feeders Chapter 6: Troubleshooting 36 of 50 Chapter 6: Troubleshooting 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 must be accomplished with the power off, ...
Page 39 - Chapter 7: Appendix
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 under recommended conditions. The company’s obligation is limited to repair or replace FOB the facto...
Page 40 - Components
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 s...
Page 41 - Specifications; Annex B Information
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 equipment that could alter the CE compliance 2. Ambient temperature: 0 degrees Celsius – Maximum (10...
Page 42 - -4 Drawings and Diagrams; Figure 6: Additive Feeder Specifications and Overall Dimensions
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 operating manual in the language of the destination country. 19. Cable support may be required for power cord, depending on final install...
Page 43 - Figure 7: Typical Additive Feeder Controllers
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 " 14 27 4 3 " 12" 6" MOUNTIN...
Page 45 - -5 Spare Parts List; Figure 8: Exploded Assembly Drawing; Part number
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 A0541207 Supply Hopper, 1.0 Cubic Foot 1 A0541208 Supply Hopper, 2.0 Cubic Foot 2 A0541225 Hopper Cover, Manual Fill 2 A0541226...
Page 47 - Figure 10: One Component Control Enclosure Parts Identification
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...
Page 48 - Figure 11: Two Component Control Enclosure Parts Identification
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...
Page 49 - -6 Returned Material Policy; Credit Returns; authorization; Warranty Returns; the manufacturer’s; Tag; Additive Feeder Safety Tags; PE
Additive Feeders Chapter 7: Appendix 48 of 50 7-6 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 ...
Page 50 - Feeder; Company Logo; City, State Zip Code; Assistance; Parts Department
Additive Feeders Chapter 7: Appendix 49 of 50 7-8 Additive Feeder Identification (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-curre...
Page 51 - Worksheet for Charting Feed Rates; Auger; - Photocopy this page for your records -
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 _...
