www.conairgroup.com USER GUIDE UGB014-0209 Software Version V4.0 TrueFeed ™ Gravimetric Feeder Co rpo r a te O f fic e : 41 2.3 12. 600 0 | I n s t ant Acc es s 2 4/7 ( Pa r ts an d Se rv ice ): 800 . 458. 196 0 | P a rts and Se rvic es : 814 .43 7.
INDEX 1. Introduction ______________________________________________________________________________________________ 1 1.1 Symbols ________________________________________________________________________________________________ 1 1.2 Terms ________________________________________________________________________________________________ 1 2. General information _______________________________________________________________________________________ 2 2.
1. Introduction Thank you for purchasing the Conair TrueFeed. This manual is addressed to operators and qualified technicians taking care of the feeding of dry additives to ensure correct use of the TrueFeed. IMPORTANT: THIS MANUAL MUST BE READ BEFORE INSTALLING THE FEEDER. KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS. Conair recommends that you record the model and serial number(s) of your equipment and the date you received it in the User Guide.
2. General information 2.1 Safety This equipment is only designed and may only be used for the feeding of dry additives. Any use that is not in conformity with the instructions is considered improper and as such frees the manufacturer from any liability regarding damage to equipment and/or persons. Before turning on the unit for the first time, ensure that the main power voltage applied is between 80 and 260 VAC.
3. Overview feeder 3.1 TrueFeed component overview 1 Stepper motor 2 Dispensing cylinder 3 Hopper 0.
3.2 Weighing frame Safety bolts (total of 4) Transport protection pin Hopper loader tube support Balance frame (when option selected) The black part is the weighing frame. Do not touch the weighing frame (and dispensing unit) while feeding, it will influence operation. Do not touch the safety bolts under the weighing platform. These are for overload protection. There must be space between the safety bolts and the frame. 3.
4. Metering principle The Dispensing cylinder® of the TrueFeed is combined with a very precise adjustable stepper motor ensuring that the additive output is accurate and consistent. The throat adapter (a mixing chamber) is designed to blend the main material and the additive homogeneously. Conair supplies a large range of machine throat adaptors that make a perfect fit to your injection molding machine or extruder.
5. Feeding systems / Capacities Depending on the application, a different feeding system may be required. Use the table below to roughly determine the best system for your application. For more detailed information contact a Conair representative. Which type of feeding system do I need with which throat adaptor? The last 3 numbers are related to the length of the feeding system.
All Conair TrueFeed feeders are equipped with the 2A (LT) stepper motor as standard. In case you are using an A30 feed auger, the 4.5A (HT) stepper motor will be supplied. The A20 auger can also be connected to the HT motor. 4.5A (HT) Stepper motor 2A (LT) Stepper motor Do not select the HT setting in the control if a LT motor is connected. This will damage the motor. If a LT motor is selected and a HT motor is connected, there will be less motor torque which can influence the feeding of additive.
6. Installation 6.1 Transport To protect the TrueFeed against damage during transport, the unit is packed in a cardboard box filled with foam. Delivery terms are FOB Franklin, PA. The buyer is responsible for the transport. Conair cannot be held liable for any damage that may occur during transportation. 6.2 Receipt Inspect the unit thoroughly upon receipt. Pass any remarks to the local agent or Conair within eight days from receipt of goods. 6.
6.4 Changing from dispensing cylinder to feed screw In relation to the maximum capacity of the dispensing cylinder, it may be necessary to change from the selected dispensing cylinder to a feed auger. The feed auger system consists of a rotating auger in a nonrotating tube. 3 5 1 2 4 To install the feed auger: 1. Detach the motor quick release clamps and remove the motor from the hopper. 2. Dismount the throat adaptor connection flange (1) by removing the four socket-head screws. 3.
BALL BEARING To clean the ball bearing, use a dry piece of textile or a smooth, dry toothbrush to remove the dust or moisture and foreign particles that may accumulate. The following points have effect on the lifetime of the ball bearing: o Abrasive materials o Temperature o Dusty / fine powder materials 6.
APPENDIX B SHOWS THE ELECTRICAL PRINT VIEW WHICH IS EXPLAINED BELOW 1. PROCESSOR BOARD The processor board is the heart of the control. The board must be fixed securely on the mainboard. There is a Mac-address that is labeled on the process board. This is the ID of the networkcard. This address can also be seen in the startup screen on the TrueFeed control display. 2. EXTERNAL TERMINAL CONNECTION This connection is used when using an external terminal (Shielded cable max. 32.8 ft {10 m}) 3.
7. Operation 7.
7.2 Start up and login Immediately after turning on the main power to the TrueFeed, the software versions will be displayed. In the first screen the software version of the terminal will be shown. Conair Terminal Version x.xx Date: January 2005 After a few seconds the second screen appears for 10 seconds. Conair TrueFeed Color in Control Vx.x SP-Vx.x MENU to continue BL Vx.x Mac-00:12:EC:xx:xx:xx Vx.x = User software version Vx.x SP-Vx.x = Language version Vx.
7.3 Keyboard lock The keyboard lock function: • Is only accessible at the LOGIN menu. • Can only be activated and deactivated with the SUPERVISOR login password. • Is only fully functional in OPERATOR and TOOLING user levels. For example: if the “Start user” setting is configured to “Supervisor”, the keyboard lock is deactivated as soon as the control is turned OFF and ON. The following screen will appear when the LOGIN menu is accessed: USER LEVEL Enter the password to set the user level.
7.4 CONFIGURATIONS For the initial setup of the TrueFeed, the control must be configured from the CONFIGURATIONS menu. Depending on the CONFIGURATIONS, some settings will be removed because they are not relevant. Highlighted Parameters are factory settings. Language Motor type Cylinder type Material type Cal dev. Control mode Prod. Mode Input mode └ Input filter Fill.
CONFIGURATIONS: Control mode (GRAVI) Gravimetric mode or (RPM) Rotating mode • Gravimetric mode (GRAVI) is set as default and functions on the basis of loss-in-weight principle. The output is measured and regulated continuously by controlling the motor speed. • Volumetric mode (RPM) can be used if no automatic feedback of the weight is required. The weighing will not function in this mode and the automatic hopper loader function will not operate. CONFIGURATIONS: Prod.
The maximum voltage that can be applied to the TrueFeed is 30 VDC. The tachometer voltage must be reduced to 30 VDC. If the tachometer generator has a higher voltage output than 30 VDC at the maximum extruder output capacity, it must be reduced. See the diagram below. Input connection Green wire + 13 12 Resistor (Rx) Yellow wire - Tachometer generator EXTRUDER Rx (kilo-Ohm) = (2,684 x (Max.
Manual: Fill in the voltage the tachometer produced by the tachometer generator at maximum extruder speed. Automatic: Let the extruder run and select Set tachometer: YES. The tachometer voltage (P1) will be taken over automatically and is linked to the set motor speed (P2) (in RPM mode) or calculated motor speed (in GRAVI mode) During production, the motor speed (P2) can be changed. The new speed is linked to the previous stored voltage and the graph will change accordingly.
If the setpoint it not reached within the set percentage: - There is a partial or complete blockage of sticky or hard flowing material. - Inaccurate feeding due to the material not being uniform in size. - Disturbance of the weight signal by mechanical blocking of the TrueFeed loadframe. The Maximum deviation setting can be set in the CONFIGURATIONS menu: Deviation alarm: xx% (1-99%) Output [gram/sec] + limit : Setpoint [gram/sec.
CONFIGURATIONS: Tooling password Password for Tooling user level, 4 numerals, default: 1111 CONFIGURATIONS: Supervisor password Password for Supervisor user level 4 numerals, default: 2222 CONFIGURATIONS: Conversion Selection of Units: Metric = European [gr/s] Imperial = US [lbs/hr] Kg/h = In extrusion mode the capacity will be shown in kg/h instead of gr/s CONFIGURATIONS: Full scale Selected load cell will be shown (read-only) CONFIGURATIONS: Modbus unit If the control is used within a Modbus network, the
7.5 Load cell calibration Two types of calibrations are available for the TrueFeed, depending on the selection made in CONFIGURATIONS: 1. Automatic - The advantage of automatic calibration over manual calibration is that the automatic calibration is self-calibrating and the probability of failures will be reduced. Also, the accuracy is higher with changes of output because a complete material curve will be produced. 2.
WEIGHT CHECK Weight: Object: Zero: • • • gr. gr. NO/YES >< ><: Weight: Object: Zero: Standstill sign. When the vibrations are too large, this sign disappears! Actual weight on the weighing scale (gram) Object weight (gram) Zero YES / NO. Reset the object weight. Zero the object weight Place the 1.1 lb {500 g} calibration weight on the hopper If the object weight is not corresponding with the weight readout in the control’s display, perform another load cell calibration.
7.6 Material pre-calibration The TrueFeed can be started in two ways: 1) Without pre-calibration of material. After pressing the “START” button the TrueFeed starts feeding at a speed that is based on default curves which are pre-programmed within the control. After start-up, the unit continues with self-calibrating to setpoint. 2) With pre-calibration of material (OFF-LINE).
How do I make a material calibration? • Navigate to the CALIBRATION menu. • Enter the material name and your production parameters. • Start calibrating. The following screen appears: CALIBRATION [TESTING BUSY] [*****] Set : 1,000 gr/s Actual : 0,945 gr/s Stop & Store : YES/NO • • • The calibration will take approximately three (3) minutes but can take longer depending on the material used and production parameters. It is possible to stop the calibration to refill the hopper, for example.
7.7 Production The rotation direction of the feeding at the front view must be to the right (Clockwise) Production (Motor On/Off) Press the “Start” button to start feeding, a question will be displayed: Fill cylinder? YES/NO. “YES” means that the dispensing cylinder will be filled before production. The start LED blinks when the unit is waiting for an input signal. The unit is feeding if the Start LED is continuously lit. When the unit is started the actual production data will be shown.
INJECTION MOLDING The following parameters can be seen in the Production screen, depending on operation or settings made within the Supervisor user level: Injection molding / Gravimetric mode Production Settings PRODUCTION SETTINGS Ref.Curve: MOVA/USER Prod Job : xxxxxxxx Material : xxxxxxxx Color % : x.xxx % Shot wth.: xxxx.x gr Dos.time : xx.x s Save job : NO/YES Test : NO/YES Ref.Curve: Type of reference curve: pre-programmed curve or user-defined curve.
EXTRUSION Extrusion / Gravimetric mode Production Settings PRODUCTION SETTINGS Ref Curve : MOVA/USER Prod Job : xxxxxxxx Material : xxxxxxxx Color % : x.xxx % Ext.cap : xxxxx.x kg/h Max tachometer: xxx,x v Set tachometer: NO/YES Save job : NO/YES Test : NO/YES Ref.Curve: Type of reference curve: pre-programmed curve or user-defined curve. Prod Job : Name of the production Job Material : Name of material calibration Color % : Color amount (%) Ext.
7.8 Auto / Manual regulation mode & save data function Two functions are available within one screen: - Regulation mode: Auto/Manual - Save data function. These two functions are not accessible within the OPERATOR user level. Regulation mode: Auto/Manual This function allows you to switch from automatic control (gravimetric) to manual control (RPM) during operation. It is only accessible when the TrueFeed’s motor is on and the control is not in the Operator user level.
7.9 Production JOB What is a Production JOB? In a production job the relevant production data will be stored. The following data will be stored in a JOB, depending on the TrueFeed’s configuration: CONFIGURATIONS settings: Control mode: GRAVI / RPM Prod. Mode: INJ / EXT Input mode: Timer / relay / tachometer PRODUCTION settings: Job description: Name of the job Shot wth.: Weight of the part color% : Color amount (%) feed time: Feeding time (sec.) Ext. cap.: Extruder capacity (kg/h) Max.
7.10 Filling the hopper MANUAL FILLING The control will automatically detect when the hopper is being manually filled. During the time that the hopper is being filled, the TrueFeed is feeding with a fixed RPM; this means that the unit is running temporarily volumetric. As soon as the hopper is filled, the TrueFeed immediately reverts to working gravimetric. AUTOMATIC FILLING (optional) Introduction Conair Truefeed feeders are capable of handling a variety of dry materials.
How the EX (support frame for external hopper loader) works The function of the support frame is to use an alternate hopper loader in combination with the TrueFeed. The support frame is equipped with a knife gate valve for filling the hopper. The valve is normally-closed. If the filling start level is reached (default 1.7 lb {800 g}) the valve opens and the hopper is filled until the EX-H level (default 5.5 lb {2500 g}). The valve will then close automatically.
General The hopper loader is only activated when the motor is On . Emergency stop. To stop the hopper loader during production, go to the HOPPER LOADER menu and switch the ME, MV or EX system to “OFF”. Hopper loader settings This part of the manual describes how to configure the hopper loader. For further technical information about the hopper loader consult the specific hopper loader manual and Appendix E and F. There are four (4) ways to fill the hopper: 1. Manually 2.
EX hopper loader (support frame for external hopper loader) EX FILLING SYSTEM EX system EX alarm time EX alarm mode Manual fill : : : : OFF/ON 31 sec OFF/ON NO/YES EX system: Alarm time: Switch ON / OFF the Support frame system. Fill Alarm [sec.], if the hopper weight is not above the filling start level within this time, an alarm will activate. EX hopper loader is ON / OFF during fill alarm. ON = The system stays activated during a filling alarm.
-For the Filling Start Weight, use a low filling start weight level as shown on the filling start weight on the previous page, a high fill start weight level will increase the amount of filling cycles. -Use a fill time long enough so that the material at least covers the sight glass in the back of the hopper. Overfilling the hopper should be avoided.
7.12 Alarms GENERAL To reset an alarm or warning press the “Stop” or “Menu” button. When an error occurs using the TrueFeed, the control’s display will indicate an error code and description. Along with the displayed error, an output contact will be switched. The control itself will sound a beeping signal and the alarm LED will illuminate.
WARNINGS All warnings are cleared automatically, except for Error code 05. It is possible to cancel a warning, but when the error remains, the warning will return after 60 seconds. This provides the operator enough time to solve the problem without having the alarm reactivate. Error 00 “Low hopper level” [free programmable] If this warning appears the material in the hopper is below the hopper empty weight 1.5 lb {700 g}. In CONFIGURATIONS menu this setting can be changed.
ALARMS Error 08 Error 09 Error 10 Error 11 Error 12 Error 13 “Motor connection failure” Motor connection is not correct. - Ensure that the motor is connected. - Check cables and connectors for damage. “Parameters damaged” Some CONFIGURATIONS parameters are incorrect. - Check the CONFIGURATIONS parameters. “Parameters set to factory defaults” All parameter settings are reset to factory defaults. - Check all parameter settings.
7.14 Event LOG Setting changes made with the control are stored in the Event Log. Each event is filed with record number, date and time. Approximately 7,000 events will be stored in the memory of the control. If the memory is filled, the latest event will be logged and the oldest event will be deleted (first in / first out shift register). It is possible to store these events to a PC. Show latest events (Steps of 1 event) EVENT LOG Record.
8. System performance System performance can be characterized by the time it takes the unit to reach the desired set point, the accuracy of the set point and the consistency of the material output. The algorithm is self-adjusting to the conditions and because the conditions vary, it cannot be predicted how long it will take the unit to adjust itself and reach a set point with certain accuracy. The following variables influence system performance: Material properties.
9. Troubleshooting Problem: The feeder does not come into specification or a maximum deviation alarm is activated. Possible causes: 1. Ensure that all cables are connected correctly. 2. Ensure that the transport protection pin is removed from the load cell safety bolt. 3. Ensure that the hopper assembly is fixed tightly to the weighing platform and that the throat adaptor is fixed tightly to the production machine. 4. Ensure that the dispensing cylinder is tightly fixed to the motor shaft. 5.
APPENDIX A: TrueFeed Print View Ribbon cable connection between terminal and mainboard Terminal (display) Ribbon cable connection between mainboard and load cell board Load cell board 1) Processor board Incl.
Important note: The maximum total output power may be 12 Watt (Valve output + alarm output) - Valve output for hopper loader (Solid state 24VDC/0.5 A) - Warning output (Solid state 24VDC/0.5 A) - Potential free relay (normally open) output for alarm level (max. 230Vac/30Vdc, 5A) - Potential free relay (normally open) output for running contact (max. 230Vac/30Vdc, 5A) This contact will be closed simultaneously when the motor of the dosing unit is running.
APPENDIX C: TrueFeed Technical Specifications Controls: Set and actual % setting for injection molding and extrusion Extrusion control by relay or tachometer Injection molding control Automatic metering time synchronization or by manual timer Manual speed and time setting Speed: Manual setting from 0.1 to 200 RPM max, in increments of 0.1 RPM. Time: Manual settings from 0.1 to 999 sec in increments of 0.1 sec.
APPENDIX D: TrueFeed Dimensions 44 TrueFeed manual
APPENDIX E: ME Hopper Loader 1. Description 1.1 What is the ME-Hopper loader? The ME system blows material from a bag, drum or container into the hopper of the TrueFeed. The hopper lid of the housing has a simple and easy-to-clean dust filter to keep any dust particles in the hopper. The hopper loader is controlled by the TrueFeed control. When the ME system is installed on the TrueFeed, the system will be triggered by the filling start weight (CONFIGURATIONS menu).
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2. Installation 2.1 Mechanical installation The hopper loader lid fits directly on the hopper of the TrueFeed. To attach the ME hopper to the TrueFeed lid, quick release clamps on the hopper are used. If the ME hopper loader is delivered subsequently instead of together with a TrueFeed unit the tube support will need to be mounted to the frame of the TrueFeed. 2.2 Compressed air installation The ME loader uses compressed air to convey material.
2.4 Electrical installation Solenoid valve The solenoid valve needs to be connected to the control of the TrueFeed. The wiring diagram for this connection is located in Appendix B. 3. Operation 3.1 How it works The ejector pipe is located near the material supply and creates a vacuum on its inlet by compressed air. This vacuum pulls on the material source and begins a flow of material through the ejector pipe.
3.3 Adjusting Compressed air flow Adjusting compressed air flow It is advised to use a flow regulator for the compressed air (not included). The air flow will determine how much material will be transferred and how fast the TrueFeed will be replenished with material, with each loading sequence. Conair recommends adjusting the air setting to its lowest possible level in order to conserve compressed air energy.
5. Troubleshooting 5.1 Conveying problems and solutions 6.
APPENDIX F: MV Hopper Loader 1. Description 1.1 What is the MV-Hopper loader How the MV works The MV system uses a 3-stage vacuum generator driven by compressed air to create a vacuum that draws material into a chamber that closes. Once the chamber is filled with material, the cone that closes the chamber will open and the material will be discharged into the hopper.
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2.1 Tube support When the MV-Hopper loader is supplied together with the TrueFeed, a tube support is installed on the load frame (see picture below). If the MV-hopper loader is delivered subsequently to a TrueFeed, the user needs to install the tube support. The tube support needs to be installed with two bolts on the frame of the TrueFeed. Function of the tube support The tube support is needed to create a loop in the flexible hoses shown in the picture below.
3. Installation 3.1 Mechanical installation 1. If the MV-loader is delivered subsequently instead of together with a TrueFeed, the tube support needs to be mounted on the frame of the TrueFeed. 2. Install the MV-loader assembly on the TrueFeed. The MV-loader lid fits directly on the hopper on the TrueFeed. Use the quick release clamps on the TrueFeed hopper to mount the MVloader. 3. Connect an ø0.31x0.23 in.
3.3 Compressed air requirements The MV-loader uses compressed air to create vacuum. The compressed air source must deliver a maximum of 58-116 PSI {4-8 bar} of clean, dry (non-lubricated), air pressure. Make connections from the solenoid and the ejector pipe with the provided compressed air tubing. Quick disconnect fittings are provided for these connections. The tubing should be cut to length for maximum efficiency of the system. Use straight cuts to assure a good square tubing end.
4. Operation 4.1 Starting up the MV-Hopper loader after installation For safety reasons, the hopper loader is only activated when the TrueFeed is in the START mode. To deactivate the hopper loader, in case of emergency, press the “STOP” button on the control. Be aware that the TrueFeed will also deactivate. 1. Adjust the pressure regulator to a minimum of 58 PSI {4 bar} and adjust to a higher value if necessary. 2. Adjust the air wand to the correct position, most applications start with Position 1. 3.
Alarm cycles [number] Number of idle fill cycles before fill alarm will appear. The number of alarm cycles needs to be more than the number of filling cycles. Example: If the amount of alarm cycles is set to 10 times, the MV-loader will try with 10 extra filling cycles to get material conveyed to the TrueFeed. If still no material is conveyed after these 10 extra cycles an alarm will be activated. 4.
5.2 Cleaning/Disassembling the loader The MV-loader assembly can easily be disassembled for cleaning without tools. To clean the MV-Loader: 1. Disconnect the main power and compressed air sources. 2. Remove the material transfer hose from the inlet pipe of the loader. 3. Disconnect the three (3) quick release clamps on the inlet flange 4. Disconnect the ø0.23x0.16 in. {ø6x4 mm} compressed air hose from the push in fitting in the lid (Pictured below). 5. Remove the stainless steel filter screen. 6.
6. Troubleshooting 6.
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APPENDIX G: We’re Here to Help Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
APPENDIX H: TrueFeed Quality Checklist Date of production Conair order number Control serial number Software version Motor serial number Unique ID code : ………………… : ………………… : ………………… : ………………… : ………………… : ………………… Check original order with internal packing list Order code : …………………………………………………………………… Cylinder check Fill in the type of cylinder ……… Fill in the cylinder length ………in {mm} Check for cylinder wrench Stepper motor check Direction motor rotation from rear view ( motor number side ) Check
