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 program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2008
All rights reserved.
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, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the parts and service department
immediately at (262) 641-8610. Have the order number and item number available. Hold
the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Additive Feeders iii
Table of Contents
CHAPTER 1: SAFETY................................................................V
1-1 How to Use This Manual.............................................................................................v
Safety Symbols Used in this Manual.....................................................................v
1-2 Warnings and Precautions......................................................................................... vi
1-3 Responsibility.............................................................................................................vii
General Responsibility......................................................................................... vii
Operator Responsibility.......................................................................................viii
Additive Feeder Safety Tags................................................................................ix
Maintenance Responsibility..................................................................................ix
Reporting a Safety Defect .....................................................................................x
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................11
2-1 Models Covered in This Manual................................................................................11
2-2 General Description...................................................................................................11
2-3 Standard Features.....................................................................................................11
Mechanical Features...........................................................................................11
Electrical Features...............................................................................................12
Controller Features..............................................................................................12
2-4 Options......................................................................................................................12
2-5 Accessories...............................................................................................................13
2-6 Safety Devices and Interlocks...................................................................................13
CHAPTER 3: INSTALLATION..................................................15
3-1 Uncrating the Equipment...........................................................................................15
3-2 Rigging and Placing the Additive Feeder..................................................................15
3-3 Electrical Connections...............................................................................................16
3-4 Setup Procedures......................................................................................................17
Determining the Desired Feed Rate....................................................................17
Calibration Procedure..........................................................................................19
3-5 Initial Start-up............................................................................................................21
Pre-Startup Checks.............................................................................................21
Starting Up the Additive Feeder ..........................................................................21
Shutting Down the Additive Feeder.....................................................................21
CHAPTER 4: OPERATION.......................................................22
4-1 Start-up......................................................................................................................22
4-2 Controller Description and Operation........................................................................22
Identifying Control Panel Indicator Lights and Switches on the Controller..........22
Timer/Counter Control Operation (Injection Molding Applications) .....................22
Timer/Elapsed Timer Control (Extrusion & Blow Molding Applications)..............23
4-3 Injection Molding Applications...................................................................................24
Steps that must be completed before the additive feeder will perform properly:.24
Injection Molding .................................................................................................24
Control Relay Connection ...................................................................................24
Field Control Programming..................................................................................24
Additive Feeders iv
Resetting the Unit to Un-Programmed State.......................................................25
JP1 (Program Enable Jumper)............................................................................25
Programming Step by Step Guide.......................................................................25
Injection Mode Application Notes........................................................................27
4-4 Extrusion Applications...............................................................................................28
Steps that must be completed before the additive feeder will perform properly:.28
Extruder Tracking Control ...................................................................................28
Control Relay Connection ...................................................................................28
Extruder Tracking Installation and Setup.............................................................29
Field Control Programming..................................................................................30
Resetting the Unit to Un-Programmed State.......................................................31
JP1 (Program Enable Jumper)............................................................................31
Programming Step by Step Guide.......................................................................31
Extruder Tracking Control Application Notes.......................................................32
CHAPTER 5: PROGRAM PARAMETER DESCRIPTIONS .....34
5-1 Defining Program Parameters...................................................................................34
CHAPTER 6: MAINTENANCE .................................................39
6-1 Preventative Maintenance Schedule.........................................................................39
6-2 Preventative Maintenance.........................................................................................40
Material Cleanout/Changeover............................................................................40
6-3 Corrective Maintenance ............................................................................................41
Auger Assembly Changeover..............................................................................41
Motor Brush Replacement...................................................................................42
CHAPTER 7: TROUBLESHOOTING .......................................43
7-1 Introduction................................................................................................................43
CHAPTER 8: APPENDIX..........................................................46
8-1 Technical Specifications............................................................................................46
Annex B Information............................................................................................46
8-2 Drawings and Diagrams............................................................................................47
8-3 Spare Parts List.........................................................................................................49
8-4 Returned Material Policy...........................................................................................52
Credit Returns .....................................................................................................52
Warranty Returns ................................................................................................52
8-5 Safety Tag Information..............................................................................................52
Additive Feeder Safety Tags...............................................................................52
8-6 Additive Feeder Identification (Serial Number) Tag ..................................................53
8-7 Technical Assistance.................................................................................................54
Parts Department ................................................................................................54
Service Department.............................................................................................54
Sales Department................................................................................................54
Contract Department...........................................................................................54
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 maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the additive feeder. We can also provide the assistance of a factory-trained technician to
help train your operator(s) for a nominal charge. This section includes instructions, checks,
and adjustments that should be followed before commencing with operation of the additive
feeder. These instructions are intended to supplement standard shop procedures performed
at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the additive feeder safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your additive feeder provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING! WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.
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 any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power before servicing or maintaining the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; DO NOT use the additive feeder in an explosive atmosphere.
; DO NOT use additive feeder outdoors or in wet environments. Moisture will
damage the motor and can create an electric shock hazard.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Use EXTREME CAUTION when working with additive feeder. NEVER put
hands or tools in or near the auger assembly when power is connected.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
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 machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
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 forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation procedures. Cooperate with co-workers to promote safe
practices. Immediately report any potentially dangerous situation to your supervisor or
appropriate person.
REMEMBER:
• NEVER place your hands or any part of your body in any dangerous location.
• NEVER operate, service, or adjust the feeder without appropriate training and first
reading and understanding this manual.
• NEVER try to pull material out of the feeder with your hands while it is running!
• Before you start the feeder check the following:
• Remove all tools from the feeder;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
hopper area;
• If your feeder has been inoperative or unattended, check all settings before starting the
unit.
• At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,
or remove safety guards. Such alteration is not only unsafe, but will void the warranty
on your equipment.
• When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
• Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual feeder action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble into the feeder
while working on it.
• DO NOT wear loose clothing or jewelry, which can be caught while working on a
feeder. In addition, cover or tie back long hair.
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 Rotating Auger
Manual
High Voltage Earth Ground
Inside Enclosure
PE Protected Earth
Lifting Point Ground
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on equipment above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your
equipment, use it. The work platform should have secure footing and a place for tools and
parts. DO NOT climb on equipment, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
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 all parts are functioning correctly.
BEFORE you turn the machine over to the operator for production, verify all equipment
enclosure panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
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 know
the model and serial number of your equipment before contacting the manufacturer for parts
or service.
Our additive feeders are designed to precisely feed up to two components before being used
in the injection molding, blow molding or extrusion processes. Additive Feeders are
configured to meet the specific requirements stated by the Customer at the time of purchase.
2-2 General Description
Our additive feeder is a highly accurate unit designed to feed one or two additives into a
stream of virgin plastic pellets prior to injection molding, blow molding, or extrusion. Such
additives may include color, regrind, or other free-flowing pelletized or granular materials.
The additive feeder may also be appropriate for other applications. Consult the manufacturer
for additional information.
2-3 Standard Features
Mechanical Features
Transport Tube
• Stainless steel augers available in ½”, ¾”, 1”, 1-1/4” and 1-1/2” sizes
• Augers/insert assemblies are interchangeable without tools
• UHMW polyethylene auger insert is durable and easily cleaned
• Calibration hatch opens without tools
• Cleanout hatch below the flood zone opens without tools and allows the supply hopper
to dump completely.
• Lightweight aluminum casting
Main Throat
• Low profile design adds only 6 inches to supply system headroom requirements
• Accommodates one or two additive feeders
• Sturdy steel construction with sight glasses to visually confirm proper operation
Supply Hopper
• 1 or 2 cubic-foot capacity
• Design based on dynamic/static material flow characteristics
• Angled hopper geometry allows use with 60º machine supply hoppers
• Easy, fast, and complete cleanout
• Sight glasses give visual level indication
• Manual fill cover standard
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 microprocessor control
• 115/1/60 supply voltage
Controller Features
• Closed-loop control constantly monitors feedback from the auger motor RPM sensor
for high accuracy and repeatability. Feed rates remain stable during main power
supply voltage fluctuations.
• Remote control mounting capability permits mounting the control panel up to 9 feet
from the feeder.
• Field-programmable display permits viewing in rpm, pounds per hour, kilos per hour,
etc., as well as high/low limits.
• Automatic and manual/calibration operation modes.
2-4 Options
Special Voltage
• 230/1/60 VAC
Timer/Counter Control
• Designed for use with cycled processes like injection molding
• Cycle timer can be set to limit the additive feeder cycle to avoid feeding straight color
if a resin supply problem occurs in conjunction with a processing machine control
relay failure.
• Batch counter provides inventory management information
• Calibration feature allows precise, repeatable sampling during setup
Timer/Elapsed Timer Control
• Designed for use with continuous processes like extrusion
• Elapsed timer provides inventory management information
• Calibration feature allows precise, repeatable sampling during setup
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 gate allows for rapid change of additives
Supply Hopper Covers
• Hopper mounting cutout for vacuum receivers
• Hopper loader mounting cutout for hopper loaders
• Blank cover available for custom cutout
Additional Auger Assemblies
• Switch augers for changing process throughputs
Mounting Adapters
• Special main throat and flanges can eliminate transitions and accommodate different
machine hoppers
2-5 Accessories
Low Level Alarm
• Audible/visual alert to allow supply hopper level to avoid feeding straight resin into
the processing machine
• Remote mount
• Advisory or process interrupt capability
• Alarm silence/acknowledge button
Drawer Magnet
• Removes tramp metal from the process stream
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 this equipment. Instead, the material contained in this section is recommended
to supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
• Identify and locate specific safety devices.
• Understand the proper use of the safety devices provided.
• Describe the function of the safety device.
Additive Feeders Chapter 2: Functional Description 14 of 55
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator 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 establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the additive
feeder; however, it is the responsibility of the personnel operating and maintaining the
equipment to familiarize themselves with the safety procedures and the proper use of any
safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on these additive feeders are primarily concerned with electrical power disconnection
and the disabling of moving parts that may need to be accessed during the normal operation
of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these additive feeders are equipped with a line
cord plug. This allows the operator or maintenance personnel to unplug the additive feeder
from its power source and tag it out. The plug can then be tagged with any number of
approved electrical lockout tags available at most electrical supply stores.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the additive feeder. Failure to do so may result in
serious injury. No one but the person who installed the lockout may remove it.
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 carefully; avoiding staples in the 1’ x 4’ wood supports.
Cut the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the skid
from the unit.
3-2 Rigging and Placing the Additive Feeder
Note: Disassemble the material transport assembly from the main throat to
ease marking, drilling and installation of the additive feeder.
If the machine throat is smaller than the additive feeder throat,
adapters are available.
1. Remove hopper from your processing machine.
2. Drill holes in both flanges of the additive feeder main throat to exactly match
the bolt hole pattern on your processing machine throat. Select a position for
easy operator access.
3. Bolt the main throat to the machine, and the machine hopper to the main throat
with the appropriate bolts, nuts and lockwashers.
4. Mount the control in a position with convenient operator access near the
additive feeder. Avoid locations with excessive dust, vibration and moisture.
Supply System Installation
If the additive feeder is to be used with an automatic loading system, install the hopper
loader, vacuum hopper, etc., in the supply hopper cover. Follow the instructions provided
with the loading system.
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 code requirements.
• The serial tag lists voltage, phase, and amp draw information
• Line voltage must be within plus or minus ten percent (±10%) of the voltage listed on
the serial tag, or damage may occur.
• Install a fused disconnect with a lockout feature in the power main leading to the
additive feeder if the unit will be wired directly to a power main.
• Make sure all electrical connections are tight.
Main Power Connection
The control is shipped pre-wired and attached to the additive feeder. Standard controls are
supplied with a power cord with the plug wired to the control unit, ready to plug into an
appropriately grounded three-prong receptacle.
Control Relay Connection
To interlock the additive feeder operation to an injection molding machine, extruder, etc.,
remove jumper (J1) from the terminal block in the control enclosure and wire in the control
relay signal from the processing machine. For injection applications the additive feeder will
automatically operate at the specified rate while the screw is turning.(see 4-3, Injection Mode
Application), for extrusion processes the additive feeder will run proportional to the speed of
the extruder. (See 4-4, Extrusion Mode Application)
Please refer to the schematics enclosed in the information packet for the latest electrical
drawings.
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 carry out these procedures in the
order given here.
Note: Before carrying out these procedures, install all equipment as
described in this section.
Determining the Desired Feed Rate
The additive feed rate is the desired amount of additive to be introduced into the process
stream per hour. To determine the feed rate, follow the procedure in this section. If the
desired feed rate is known, go to the calibration procedure in the next section. The charts in
figures 1 and 2 on the following page provide conversion and rate charts to assist you in your
calculations.
For Cyclical Processing (Injection Molding, etc.)
To set up an additive feeder for cyclical processing, you need to know shot size, recovery
time, and the letdown ratio.
Cyclical Processing Equation:
Shot Size (oz)
Recovery time (sec) x Letdown (ratio or %) x 225 = Feed Rate (lbs./hr.)
Example:
Shot size = 8 ounces
Recovery time = 5 seconds
Letdown ratio = 20:1
8 oz./5 sec. X 1/20 = 0.08 = Desired feed rate
To convert to lbs./hr.: 0.08 oz/sec x 225 = 18 lbs./hr.
For Continuous Processing (Extrusion, etc.)
To set up an additive feeder for continuous processing, you need to know the total process
throughput and the desired additive percentage or letdown ratio.
Continuous Processing Equation:
Total throughput (lbs./hr.) x percentage of additive = Feed rate
Example:
Total throughput = 100 pounds per hour
Percentage of additive = 2%
100 lbs./hr. x 0.02 = 2 lbs./hr. feed rate
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/hr
55 lb/hr
7 lb/hr
110 lb/hr
1/2" auger 3/4" auger 1" auger 1 1/4" auger
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 hatches are open.
Equipment Needed:
• Scale
• Sample container
• Timer- stopwatch, watch/clock w/second hand
Procedure
1. Close cleanout and calibration hatches.
2. Fill the additive supply hopper.
3. Weigh the empty sample container.
4. Swing open the calibration hatch near the main throat.
5. Set the controller to a desired RPM.
6. Place the sample container below the calibration hatch.
7. Hold the three-position motor switch in the Manual position for about a minute.
This lets the new setpoint stabilize and fills the auger flights with material. Discard
the first sample.
8. Position the empty scale container below the calibration hatch and hold the three-
position motor switch in the Manual position for exactly one minute.
Note: If your additive feeder is equipped with the timer option, set the timer to
one minute and put the three-position switch in the Manual position.
Operation will automatically stop after one minute.
9. Weigh the sample container. Subtract the weight of the container and multiply by
60 to determine the pounds per hour feed rate.
10. Adjust the auger rpm and repeat the calibration process until the desired feed rate is
achieved.
Note: To speed the calibration procedure, reduce trial and error auger rpm
settings and zero in on the desired feed rate. Chart the calculated feed
rates from a few rpm settings on graph paper. Draw a straight line
between the coordinates to establish a customized feed rate curve for
the actual operating conditions. A sample graph is provided on the
next page; graph paper is included in the back of this manual for use
with your feeding processes.
Additive Feeders Chapter 3: Installation 20 of 55
Examples:
This example shows how to extrapolate a desired feed rate of 3 lbs./hr., based on the feed
rates of 3 trial rpm settings.
Observed Feed Rates
Sample 1 = 2 pounds per hour @ 20 rpm
Sample 2 = 4 pounds per hour @ 40 rpm
Sample 3 = 6 pounds per hour @ 60 rpm
In this example, a feed rate of 3 lbs./hr. would be about 30 rpm.
0
1
2
3
4
5
6
7
0
10 20 30 40 50 60 70
8
Trial RPM settings
Calculated
feed rates
(lbs/hr)
@ the
trial RPM
1
4
2
3
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