Sterling AF-XXX User manual

Brand: Sterling

Model: AF-XXX

Type: User 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 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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Sterling AF-XXX User manual

Brand: Sterling

Model: AF-XXX

Type: User manual

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