600 feeder instruction manual - used food - · pdf file600 feeder instruction manual r ......

600 FeederInstruction Manual

R

RA Unit ofBULK SOLIDS METERING

Information contained in this manual is subject to change withoutnotice and does not represent a commitment on the part ofAccuRate. No part of this manual may be reproduced or transmittedin any form or by any means, electronic or mechanical, includingphotocopying and recording, for any purpose, without the expressedwritten permission of AccuRate.

© 2000 SCHENCK AccuRate All rights reserved.

Publication # IMF60000 / 0115

TABLE OF CONTENTSSafety Information ..................................1

Reference Information............................3Safe Handling and Transit ..............................................6

Installation ..............................................9Unpacking Instructions ...................................................9Support Structure ...........................................................9Electrical Connections..................................................10Grounding the System..................................................11

Introduction ...............................................................11Procedure..................................................................11

Assembly of Leveling Feet ...........................................12Cleaning Feeder Prior To Use ......................................13Initial Starting Procedures ...........................................13

Operation...............................................15Setting the Potentiometer ............................................15Starting the Feeder.......................................................16Stopping the Feeder.....................................................16

Calibration ............................................17Calibrating the System Using the Touchpad Settings ..17Calibrating the System Using an Auto Input Signal......19

Method One .............................................................19Method Two .............................................................21

Accuracy.......................................................................22Calculating Standard Deviation ................................23

Maintenance .........................................29Disassembly of Panels, Helix and Hopper ...................29

SCHENCK AccuRateInstruction Manual

Instruction Manual 600 Feeder IMF60000 / 0115SCHENCK AccuRate i

Panel Removal .........................................................29Hopper Removal.......................................................31Helix and Nozzle Changes .......................................31

Sprockets and Chains ..................................................33Chain Removal .........................................................34Sprocket Replacement .............................................34Motor Sprocket .........................................................34Idler Sprocket............................................................34Link Assembly Sprocket ...........................................35Chain Installation/Adjustment ...................................36

Link Assembly ..............................................................37Eccentric Changes ...................................................38

Agitation Paddles .........................................................39Motor and Gear Reducer..............................................41

Removal and Installation ..........................................41Motor Brush Replacement ........................................42

Touchpad Potentiometer ..............................................43Setup Jumper ..........................................................43Chip Switch and Fuse ..............................................43

Lubrication....................................................................43Chains.......................................................................45

Cleaning and Sanitizing................................................45Rinsing......................................................................46Cleaning....................................................................46Sanitizing ..................................................................46

Preventive Maintenance Schedule...............................47

Troubleshooting....................................49

Parts Lists..............................................53


ii IMF60000 / 0115 Instruction Manual 600 FeederSCHENCK AccuRate

Safety Information

IMF60000RV110596

The following section describes thesafety information contained in thismanual. Please read ALL of the safetylabels to avoid DEATH, PERSONALINJURY, or DAMAGE TO THEMACHINE.

DANGERThe presence of this symbolindicates that the operation,procedure, or item beingdescribed has the potential tocause SEVERE INJURY orDEATH. Use EXTREME cautionand follow all safety guidelineswhen encountering this symbol.

WARNINGThe presence of this symbolindicates that the operation,procedure, or item beingdescribed has the potential tocause SEVERE INJURY. UseEXTREME caution and follow allsafety guidelines whenencountering this symbol.

CAUTIONThe presence of this symbolindicates that the procedure oritem being described may causedamage to the machine and/orloss of product. Follow allinstructions to prevent this fromoccurring.

NOTE: The presence of this symbolindicates a precaution to be takenduring an operation or procedure. Itmay also point out helpful hints tomake an operation easier tocomplete.


Instruction Manual 600 Feeder IMF60000 / 0115 1SCHENCK AccuRate

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2 IMF60000 / 0115 Instruction Manual 600 FeederSCHENCK AccuRate

Reference Information

IMF60000RV110596

Congratulations on your purchase of aquality built AccuRate feeder!

AccuRate feeders are designed to feeddry materials in a manner that allows forthe measurement of the material beingfed. The feeder is intended to be acomponent of your larger system andprocess.

Please take a few moments to read thismanual. It contains information that willbe helpful in the installation, operation,and maintenance of your feeder. Toenable us to fill your parts orderspromptly and correctly, please take amoment to fill in the above information.When ordering replacement parts, orderby the part number and descriptionshown in the parts list located at the endof this manual. Also, have the aboveinformation ready to give to theCustomer Service Representative.

NOTE: This manual is divided intotwo main sections. The first sectioncontains the instructions forinstallation, calibration, operation,and maintenance to your feeder. The

second section contains the partslist for the model feeder youpurchased. If the parts list does notmatch the machine that youpurchased, contact your CustomerService Representative. See page 5for details.

To locate your equipment serialnumber, remove the front cover panelassembly, see “Disassembly of Panels,Helix and Hopper” on page 29. As youare facing the material discharge side ofthe feeder, the equipment serial numberis stamped on the plate, located on thelower right hand corner post of thefeeder frame.

Your feeder was shipped with asprocket layout which is shown inFigure 1 on page 3. For moreinformation regarding installation,operation, maintenance and service,please contact your CustomerService Representative. See page 5for details.



· EQUIPMENT SERIAL NO ___________________________

· DATE OF START-UP ___________________________

· START-UP BY ___________________________



Single DriveUnits

Dual DriveUnits

Helix Sprocket_________ Teeth_________ Teeth

Agitation Motor Sprocket_______Teeth_______Teeth

Helix Motor Sprocket________ Teeth________ Teeth

Motor Sprocket________ Teeth________ Teeth

Helix Sprocket________ Teeth________ Teeth Link Assembly

_______Teeth_______Teeth

Link Assembly_______Teeth_______Teeth

Figure 1. Sprocket Configuration



Shaded

Are

aS

erv

ice

Zone

1U

nshaded

Are

aS

erv

ice

Zone

2

Se

rvic

eZ

on

e1

Co

nta

ct

Se

rvic

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on

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Figure 2. Service Zone Map

Safe Handling and TransitThe AccuRate feeder should betransported on or attached to a shippingpallet whenever possible.

When a pallet is not available, it isnecessary to partially disassemble thefeeder to properly attach the liftingstraps or chains. To transport the feederwithout a pallet, the feeder hopper mustbe removed. Refer to the “Disassemblyof Panels, Helix and Hopper”, page 29.See Figure 4.

Use a forklift or overhead crane to liftand move feeder at all times. SeeFigures 3 and 4.



B

C

A. Overhead Lift C. Feeder

B. Lifting Straps or Chains D. Pallet

A

D

Figure 4. Transit Using an Overhead Lift

AB

C

A. Fork Truck C. Pallet

B. Feeder

Figure 3. Transit Using a Fork Truck



AA

B

C

D

A. Transport Strap Location

(Through top of feeder frame

with hopper removed)

B. Transport Straps or Chains

C. Chain or Straps to Hoist

D. Feeder With Hopper Removed

Figure 5. Transit Without a Pallet

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Installation

The contents of this manual should bethoroughly reviewed and understoodprior to installing and operating theequipment.

Unpacking InstructionsImmediately after removing the feederfrom the carton, check for any damagethat might have occurred duringshipment. If damage has occurred,promptly file a claim with the deliverycarrier. Whenever possible, unpack theequipment at the installation site.

Support StructureThe support structure for the feedermust be rigid, flat and have a surfacearea equal to, or larger than the feederbase. Four adjustable feet are suppliedwith each feeder and should bethreaded into the corners of the feederbase. The feeder should then be leveledinto its permanent position. Allowadequate clearance around the feederfor inspection and servicing.

In some applications, a hopperextension or another piece of equipmentis attached to the top of the feeder. Toattach the equipment, a slightmodification is necessary:

1. Remove the hopper and locate thefour marks, or “dimples” in the bottomof the hopper. (The steps for hopperremoval can be found on page 31.)See Figure below for the location ofthe marks.

2. Drill four holes of the required size inthe hopper at the marks.

NOTE: This is the ONLY place thehopper should be drilled. Do not drillor puncture the hopper in any otherlocation. Doing so voids allwarranties.



A. Location of Drill Marks (Drill Here)

A

Figure 6. Location of Marks to Drill Hopper

A. Location of drill marks (drill here)

3. When the drilled hopper is installed,the holes line up with tapped holes inthe frame. See Figure 7.

4. Other equipment may now beattached to the feeder using fourbolts.

WARNINGDO NOT support the feeder by thefour bolts. The feeder is notdesigned to be supported in thislocation. Contact your CustomerService Representative if you haveany questions. See page 5 fordetails.

Electrical Connections

DANGERAll electrical connections must bemade by a qualified electrician.SEVERE INJURY or DEATH mayresult if the machine is wiredincorrectly. All wiring mustconform to local electrical codes.

The following electrical connectionsneed to be made:

• Controller

• Motor(s)

See the wiring schematic supplied withthis manual for correct wiring locationand proper AC input voltage. If youhave any questions concerning thewiring of your feeder, contact yourCustomer Service Representative.See page 5 for details.



A. Drilled and Tapped Holes in Frame

A

Figure 7. Location of Mounting Holes in Frame

A. Drilled and tapped holes in frame

Grounding the System

Introduction

Some systems produce excessivestatic that may cause problems infeeding material properly. Thefollowing is the recommendedprocedure for properly grounding thecomponents of the system.

Procedure

Materials Needed

#10 wire with ring lugs cut to sizesmeasured in step 1.

1. Measure the following distancesand cut sections of wireaccordingly:

• From a stud on the hopperextension to an attachment point



Figure 8. Attachment of Ground Wires

on the main frame of the feeder(Item F, Figure 8).

• From one side panel mountingscrew on the scale to theattachment point on the feederframe (the same point on feederframe can be used to attach allthree ground wires) (Item G,Figure 8).

• From the nozzle to a stud on thefeeder frame (Item H, Figure 8).

2. Attach one end of a wire from astud on the hopper extension to astud on the main frame of thefeeder.

3. Attach a wire from one side panelmounting screw on the scale to astud on the main frame of the feeder(use the same feeder stud used instep two).

4. Attach a ground wire from TrueEarth to the same mounting screwused in step three.

5. Attach a ground wire from thenozzle to a stud on the feederframe.

NOTE: This ground must beattached to True Earth inaccordance with National ElectricalCode Specifications.

Assembly of Leveling FeetA large plastic bag containing fourleveling foot assemblies, one handlewith mounting screws, and oneinstruction manual is included withyour feeder. Also included is a helixand a nozzle.

If you have not received all of theseitems, please contact your CustomerService Representative. See page 5for details.

1. Locate the four threaded holes inthe bottom corners of the feederframe.

2. Turn the lock nut on the levelingfoot until it stops in a position asclose to the black rubber pad aspossible. See Figure 9.

3. Next, thread these leveling footassemblies clockwise into thethreaded holes in the bottomcorners of the feeder frame. SeeFigure 10.

4. Turn these foot assemblies untildesired height for the feeder isachieved.

5. Place a level on the feeder.

6. Adjust feet until feeder is level andtighten the lock nuts against thefeeder base.



Cleaning Feeder Prior ToUseThe feeder should be completelywiped down prior to use. Use a dampcloth to wipe out any residue left in thehopper or on the panels.

WARNINGNEVER use a hose to wash downthe unit. This could causedamage to the machine andincrease the possibility ofelectrical shock and SEVEREINJURY. Contact your CustomerService Representative if youhave any questions. See page 5for details.

Initial Starting ProceduresTo start the feeder:

1. Make sure the power has beenconnected to the correct AC inputvoltage (see wiring schematic in theback of this manual for correctvoltage specifications for yourfeeder).

2. Start the feeder following thedirections outlined in the“Operation” section on page 15.

3. To change the speed of the helix,use the arrow keys on the speedcontrol potentiometer labeled FeedRate. For more information onsetting the potentiometer. See page15.

4. Before placing dry material into thehopper, run the feeder for a shortperiod of time to become familiarwith its operation. While the feederis running, check the helix rotation.The helix should be rotatingcounterclockwise when viewed fromthe discharge end of the feeder.



A. Foot B. Lock Nut

A

B

Figure 9. Foot Assembly

A. Foot B. Lock Nut

A

B

Figure 10. Installing Foot Assembly to Frame

A. Feeder Frame B. Leveling Feet

See Figure 11. If the helix is notrotating counter-clockwise, themotor has been wired incorrectly. Ifyou have any questions, pleasehave your serial number readyand contact your CustomerService Representative. See page5 for details.

5. After running the feeder for the firsteight hours, check the chaintension. The chain may stretchslightly in the first eight hours of useand may need additionaladjustment. For chain adjustmentinstructions, see the “Sprockets andChains” section on page 33.

6. The last item needed to completethe installation is to calibrate thefeeder. This can be done byfollowing the instructions in the“Calibration” section starting onpage 17.



A. Helix

A

Figure 11. Correct Helix Rotation.

A. Helix

Operation

IMF60000RV110596

WARNINGKeep hands and loose clothingaway from moving helix. Helixcould cause SEVERE injury.

NOTE: If your feeder has beenordered with AC motors, refer to theAC Motor Control manual forcorrect operation.

Setting the PotentiometerThe potentiometer allows the operatorto set the motor RPM associated witheither the agitation or the helix.

To set the Touchpad Potentiometer,see the following control descriptions:

DISPLAY - This shows the presentsetting of the potentiometer. The valueshown in the display is the percentageof the feeder’s capacity. For example,if 750 is displayed, the potentiometeris set at 75% capacity.

NOTE: The decimal point willappear when the feeder is started.

“UP” ⇑ ARROW BUTTONS - Thesethree buttons raise the number valuein the display. The button on the rightraises the “ones” digit, the button inthe center raises the “tens” digit, andthe button on the left raises the“hundreds” digit.

“DOWN” ⇓ ARROW BUTTON -These three buttons are similar to the“Up” arrow buttons, but pressing oneof these buttons causes thecorresponding digit to decrease.



DISPLAY

"UP" ARROWBUTTONS

"DOWN" ARROWBUTTONS

START / STOPBUTTON

Figure 12. Touchpad Potentiometer

START/STOP BUTTON - This buttontoggles between the start or runningmode and the stop mode of the motor.When power is being supplied to themotor, a decimal point is lit upbetween the center and the rightdecimal position.

Starting the FeederOnce the desired potentiometersetting(s) is obtained, fill the hopperwith the desired material and start thefeeder:

1. For units with one motor for thehelix and agitation, press theSTART/STOP button (or ON/OFFswitch) to begin operation.

DANGERNEVER operate the feeder withANY of the panels removed. Thepanels protect the operator frommoving parts and electricalconnections that could causeSEVERE INJURY or DEATH to theoperator.

2. For units with separate helix andagitation motors, start each of themotors by pressing thecorresponding START/STOPbuttons (or ON/OFF switches) tobegin operation. While the feeder isin operation, check the dischargeoccasionally to make sure that it isclear, also check that the hopper isfull of material.

Stopping the FeederTo stop the feeder, simply press theSTART/STOP button (ON/OFFswitch).

WARNINGALWAYS STOP the feeder anddisconnect the power wheneverperforming any maintenance tothe unit, or to free any objectsthat may have become lodged inthe helix. The helix could causeSEVERE INJURY if contact ismade while it is in operation.



Calibration

The correct feed rate is determined bythe speed, bulk density of the material,and size of the helix in the feeder.Calibration of the feeder must be donewith the actual material that will beused. The following equipment isneeded:

• An empty container large enoughto catch all the material when thefeeder is run at potentiometersetting of 900 for one minute.

• A scale to weigh the containerand material.

• A stop watch.

Calibrating the SystemUsing the TouchpadSettingsThis procedure will establish a manualfeed rate graph. To begin thecalibration process:

1. Run the feeder empty forapproximately five minutes prior tocalibration to allow the DC motor towarm up.

2. Weigh an empty container andrecord the weight here.

EMPTY CONTAINERWEIGHT_________

3. Fill feeder with the material that is tobe processed.

4. With the manual/auto switch inmanual, turn the feeder ON and rununtil the discharge nozzle is full ofmaterial.

5. Set the feed rate potentiometer at the100 setting (10% of maximum speed).For information on setting thepotentiometer, see “Setting thePotentiometer” on page 15.

6. Using the empty container weighed instep 2, collect 10 one-minute samplesusing a stopwatch. Weigh and recordeach Sample Weight on theCalibration Data Chart found in Figure15 on page 25. Determine the NetWeight of each sample by subtractingthe empty container’s weight (thevalue in step 2) from the sampleweight see Equation #1, Figure 13.Record each Net Weight on theCalibration Data Chart found in Figure15 on page 25.

7. Obtain the Average Net Weight ofthese samples by adding the 10recorded Net Weights and dividing by10. See Equation #2 and #3, Figure13. Record Average Net Weight onthe Calibration Data Chart found inFigure 15 on page 25.

8. If you wish to show the feed rate nlbs/hr or kg/hr, multiply the Average



Net Weight by 60. See Equation #4,Figure 13. Record each of thesevalues on the Calibration Data Chartfound in Figure 15 on page 25.

9. Turn to the Calibration Graph foundin Figure 17 on page 27. On thebottom of this graph are 10 boxesnumbered 1 through 10.

10. Place the Averaged Net Weightarrived at in step 7 in the boxnumbered 1 (at 100 setting).

11. Repeat this procedure (steps 6and 7 using the data chart onpage 26) at the 900 setting on thefeed rate potentiometer (90% ofmaximum).

12. Turn to the Calibration Graphfound in Figure 17 on page 27.On the bottom of this graph are10 boxes numbered 1 through 10.



EQUATION #1

Sample Weight - Container Weight (from step 2) = Net Weight

EQUATION #2

( )S = Net Weight S1+S2+S3+S4+S5+S6+S7+S8+S9+S10 = Total Net Weight

EQUATION #3

EQUATION #4

Average Net Weight x 60 = Average Net Weight (in lbs per hour or kg per hour)

EQUATION #5

(Value in box 9 - Value in Box 1) = Interval Value8

EQUATION #6

Box Number x Interval Value = Feed Rate value in box above number

Figure 13. Equations for Feeder Calibration

Total Net Weight10 = Average of Net Weight (enter value on graph in box 9)

13. Place the Averaged Net Weightarrived at in step 11 in the boxnumbered 9 (at 900 setting).

14. Subtract the value in box one fromthe value in box 9. This value is theSpan Value. Divide the Span Valueby 8. This new value is theInterval Value. See Equation #5,Figure 13.

15. Determine the value for eachremaining box:

• Multiply the Interval Value by thenumber in each box (in Figure 17)to derive the Feed Rate Value forthat box. Enter this value in theblank box above the number. SeeFigure 13, Equation # 6.

16. Establish the value of the smallergraph divisions by dividing theinterval value by 10. This value isthe incremental value for eachindividual small box.

NOTE: The graph line can be extendedto show values greater than 90% (900potentiometer setting) or less than10% (100 potentiometer setting).

The feed rate at any one setting may nowbe determined from the graph or fromactual testing. You may want to repeatsteps 2 through 8 at a 500 setting (50%of speed) to make sure your 50% feedrate falls on the plotted line.

Remember that various feed rates arereached by using different size helix andsprocket combinations. If your desired

feed rate is not being obtained in normalsettings, contact your CustomerService Representative. See page 5 fordetails.

Calibrating the SystemUsing an Auto Input SignalThe following procedure is used tocalibrate a system that uses a 0 V to 10V input signal or a 4mA to 20mA signal tocontrol the feed rate.

There are two methods that can be usedto calibrate a system that uses an inputsignal to regulate the feed rate. Methodone creates its own unique feed rategraph. Method two uses the manualcalibration graph as a base line andadjusts the signal isolator boardpotentiometers so that the input signalfeed rate graph matches the manual feedrate graph.

Method One

The following is a description ofcalibration of your volumetric feederusing an input signal. This method willestablish an input signal feed rate graphseparate from the manual feed rategraph.

1. Wire the input signal (4mA to 20mA or0V to 10V) to the terminals listed in thedrawing for the auto input.

2. Switch the auto/manual switch to auto.

3. Force the input signal to its 10% ofmaximum value (1V or 5.6mA).




5. Weigh an empty container andrecord the weight here.EMPTY CONTAINERWEIGHT_________


7. Turn the feeder ON and run until thedischarge nozzle is full of material.

8. Using the empty container weighedin step 5, collect 10 one-minutesamples using a stopwatch. Weighand record each Sample Weight onthe Calibration Data Chart found inFigure 15 on page 25. Determinethe Net Weight of each sample bysubtracting the empty container’sweight (the value in step 5) from thesample weight. See Equation #1,Figure 13. Record each Net Weighton the Calibration Data Chart foundin Figure 15 on page 25.

9. Obtain the Average Net Weight ofthese samples by adding the 10recorded Net Weights and dividingby 10. See Equation #2 and #3,Figure 13. Record Average NetWeight on the Calibration DataChart found in Figure 15 on page25.

10. If you wish to show the feed ratein lbs/hr or kg/hr, multiply theAverage Net Weight by 60. SeeEquation #4, Figure 13. Recordeach of these values on the

Calibration Data Chart found inFigure 15 on page 25.

11. Turn to the Calibration Graphfound in Figure 17 on page 27. Onthe bottom of this graph are 10boxes numbered 1 through 10.

12. Place the Averaged Net Weightarrived at in step 10 in the boxnumbered 1 (at 10% setting).

13. Repeat this procedure (steps 8through 10 using the data chart onpage 24) with the input signalforced to 90% of the maximuminput value.

14. Turn to the Calibration Graphfound in Figure 17 on page 27. Onthe bottom of this graph are 10boxes numbered 1 through 10.

15. Place the Averaged Net Weightarrived at in step 13 in the boxnumbered 9 (at 90% of themaximum input value).

16. Subtract the value in box 1 fromthe value in box 9. This value isthe Span Value. Divide the SpanValue by 8. This new value is theInterval Value. See Equation #5,Figure 13.

17. Determine the value for eachremaining box:

• Multiply the Interval Value bythe number in each box (inFigure 17) to derive the FeedRate Value for that box. Enterthis value in the blank box abovethe number. See Figure 13,Equation # 6.



18. Establish the value of the smallergraph divisions by dividing theinterval value by 10. This value isthe incremental value for eachindividual small box.

NOTE: The graph line can beextended to show values greaterthan 90% or less than 10% of themaximum input value.

The feed rate at any one setting maynow be determined from the graph orfrom actual testing. You may want torepeat steps 2 through 5 at a 500setting (50% of speed) to make sureyour 50% feed rate falls on the plottedline.

Remember that various feed rates arereached by using different size helixand sprocket combinations. If yourdesired feed rate is not being obtainedin normal settings, contact yourCustomer Service Representative.See page 5 for details.

Method Two

The following is a description ofcalibration of your volumetric feederusing an input signal. This methoduses the manual calibration graph as abase line and adjusts the signalisolator board potentiometers so theinput signal feed rate graph matchesthe manual feed rate graph.

1. Wire the input signal (4mA to 20mAor 0V to 10V) to the terminals listedin the drawing for the auto input.

2. Calibrate your system using the“Calibrating the System Using theTouchpad Settings” procedurestarting on page 17.

3. Once a manual feed rate graph isestablished, switch the touchpadauto/manual switch to auto.

4. Force the input signal to 10% of itsmaximum value (1V or 5.6mA).


6. Weigh an empty container andrecord the weight here.EMPTY CONTAINERWEIGHT_________


8. Turn the feeder ON and run untilthe discharge nozzle is full ofmaterial.

9. Using the empty container weighedin step 6, collect 10 one-minutesamples using a stopwatch. Weighand record each Sample Weight onthe Calibration Data Chart found inFigure 15 on page 25. Determinethe Net Weight of each sample bysubtracting the empty container’sweight (the value in step 6) from thesample weight. See Equation #1,Figure 13. Record each Net Weighton the Calibration Data Chart foundin Figure 15 on page 25.

10. Obtain the Average Net Weight ofthese samples by adding the 10



recorded Net Weights and dividingby 10. See Equation #2 and #3,Figure 13. Record Average NetWeight on the Calibration DataChart found in Figure 15, page 25.

11. If you wish to show the feed rate inlbs/hr or kg/hr, multiply the AverageNet Weight by 60. See Equation #4,Figure 13. Record each of thesevalues on the Calibration Data Chartfound in Figure 15 on page 25.

12. Repeat this procedure (steps 9through 11 using the data chart onpage 26) with the input signal forcedto 90% maximum value.

NOTE: Steps 13 and 14 are used toadjust the input feed rate to matchthe manual calibration feed rate.

13. Using the manual setting feed rategraph as a base line, compare theinput signal feed rate values.

14. Using the zero and spanpotentiometers on the signal isolatorboard, adjust the output signals inthe direction needed to match thevalues recorded in box 1 and box 9on the manual feed rate graph.

15. Repeat steps 13 and 14 until theinput feed rate chart matches themanual feed rate chart.

The feed rate at any one setting maynow be determined from the graph orfrom actual testing. You may want torepeat steps 9 through 11 at a 12mA or5V setting (50% of speed) to make sure

your 50% feed rate falls on the plottedline.

Remember that various feed rates arereached by using different size helix andsprocket combinations. If your desiredfeed rate is not being obtained in normalsettings, contact your CustomerService Representative. See page 5for details.

AccuracyHere are terms that are commonly usedwhen talking about accuracy:

Mean

This is the average of the samples ormeasurements taken.

Where:

n = number of samples

xi = sample measurements

X = mean

Standard Deviation

Standard Deviation is the amount theitem being measured deviates from themean. In this case, the weight ofmaterial being fed.

Sigma (s)

Sigma is a unit of standard deviation.

Normal Distribution

If the frequency of the weights of thesamples taken were plotted on a graph,the graph would form a bell curve. See



Figure 14. The bell curve illustrates howthe samples fall around the mean.

Most often, deviation, rather thanaccuracy, is considered and usedinterchangeably. As an example, avolumetric feeder traditionally deviatesfrom the mean +2%. Loss-In-Weightfeeders deviate approximately +0.5%.

Deviation for material feedingequipment is generally stated at 2Sigma or two standard deviations. After30 one-minute tests (minimum), themean and standard deviation arecalculated. Standard deviationdescribes how the 30 samples aredistributed around the mean. Whileonly 68.3% of the sample population willfall within one standard deviation of themean, 95.5% will fall within twostandard deviations and 99.7% will fallwithin three standard deviations.

When comparing tests betweenfeeders, it is important to compare allfeeders at the same standard range ofdeviation.

We hope this helps you understand thedeviation (accuracy) statementstypically made with this type ofequipment. For more detailedinformation contact, your CustomerService Representative. See page 5for details.

Calculating Standard Deviation

The following steps are used tocalculate the standard deviation:

1. Take 30 one minute samples fromyour feeder in the same manner usedin calibrating the machine (Step 1through 7 on page 17).

2. Add these numbers together anddivide by the number of samples.This is the MEAN.

NOTE: The examples in the followingsteps show how the percent ofaccuracy is derived.

3. Next, subtract the MEAN found instep 2 from each of the sampleweights and square the difference.Follow these steps for each of thesample weights.

Example:Mean = 110, Sample weight = 111111 - 110 = 1, 12 = 1

4. Total the results of all of thecalculations done in step 3.

Example:Numbers found in step 3 = 1.5, 1, .5,and .25

1.5 + 1 + .5 + .25 = 3.25

5. Subtract 1 from the number ofsamples.

Example:Number of samples = 44 - 1 = 3



6. Divide the number found in step 4 bythe number found in step 5.

Example:325

3108

..=

7. The square root of the number foundin step 6 is the standard deviation.

Example:108 104. .=

8. Multiply the standard deviation by 2to get two standard deviations.

Example:1.04 x 2 = 2.08

9. Divide the calculated standarddeviation figure by the mean andmultiply by 100. This will give you thepercent error of your system.

Example:208110

0189.

.=

.0189 x 100 = 1.89%



X

Average

X-sX-2sX-3s X+s X+2s X+3s

Figure 14. Standard Deviation Curve



SpeedPotentio-meterSetting100

OneMinuteSampleNumber

SampleWeight

ContainerWeight

Net Weight

1__________

__________

__________

2__________

__________

__________

3__________

__________

__________

4__________

__________

__________

5__________

__________

__________

6__________

__________

__________

7__________

__________

__________

8__________

__________

__________

9__________

__________

__________

10__________

__________

__________

__________

Total NetWeight

__________

Average NetWeight

Figure 15. Calibration Data for 100 Setting



SpeedPotentio-meterSetting900

OneMinuteSampleNumber

SampleWeight

ContainerWeight

Net Weight

1__________

__________

__________

2__________

__________

__________

3__________

__________

__________

4__________

__________

__________

5__________

__________

__________

6__________

__________

__________

7__________

__________

__________

8__________

__________

__________

9__________

__________

__________

10__________

__________

__________

__________

Total NetWeight

__________

Average NetWeight

Figure 16. Calibration Data for 900 Setting



000

Figure 17. Calibration Graph

Maintenance

IMF60000RV110596

DANGERIf not handled properly thismachine could cause SEVEREINJURY or DEATH. Maintenanceshould only be conducted bytrained, authorized personnel. Nochanges or repairs should bemade while feeder is in operation.Disconnect and lock out powerbefore making changes orrepairs.

To easily locate parts mentioned inthis section, refer to the drawing foryour model in the “Parts Lists” section,page 53.

Disassembly of Panels,Helix and HopperPanels must be removed for mostmaintenance. Some maintenance mayrequire removal of helix and/or hopper.The following instructions outline theseprocedures:

Panel Removal

1. Loosen screws and remove panel.See Figure 18.

NOTE: Remove cable (unscrew)from touchpad when removing sidepanel with touchpad potentiometer.



Figure 18. Removing Panels

H. Nozzle

A. Helix

. Hopper Bolts (4) E. Hopper

F. Rear ClampD. Inside Clamp

C. Outside Clamp

A

B

C

DE

F

H

B

Hopper Removal

To remove the hopper, refer to Figure19 and do the following:

1. Empty material from hopper.Remove front and side panels.

2. Loosen front inside and outsidehose clamps (items C and D Figure19). Remove nozzle.

3. Remove helix by turning itcounterclockwise when looking at itfrom the nozzle side.

4. Remove four bolts located under theleft and right side of frame lip. SeeFigure 19.

5. Loosen rear hose clamp and lifthopper from frame.

To install, reverse procedure.

See Helix and Nozzle Replacement,page 31, for proper installation ofnozzle and helix.

Helix and Nozzle Changes

NOTE: When helix size changes, thenozzle must also change.

To replace the helix and/or nozzle:

1. Loosen front inside and outsidehose clamps. Remove nozzle.

2. Remove helix by turning itcounterclockwise when looking at itfrom the nozzle side.



Detail A See Detail A

Bevel on quill is

flush with hopper

Figure 20. Cross Section of Feeder Showing Quill



90 Degrees

Top View

90 Degrees

Side View

Figure 21. Proper Installation of Nozzle

Incorrect Helix/Nozzle ArrangementIncorrect Helix/Nozzle Arrangement

Correct Helix/Nozzle Arrangement

Figure 22. Proper Helix Installation

3. Position helix on drive shaft and turnit clockwise.

4. Install nozzle, making it flush withend of helix.

5. Install and secure inside andoutside clamps.

When installing the nozzle on thefeeder, it is absolutely necessary thatthe nozzle is square to the feeder (seeFigure 21) for proper alignment. If thenozzle is not installed properly,excessive wear will occur to movingcomponents.

When installed, the helix should notextend past the end of the nozzle andshould remain flush with the end of thenozzle. See Figure 22.

CAUTIONInside clamp must be around thenozzle and hopper to seal thisarea. Outside clamp must go overnozzle, making sure it is alsosecured under metal saddle andtighten.

CAUTIONMake sure the rear clamp is overvinyl protrusion on lower rear ofhopper. Hopper should be overquill. Inner portion of hoppershould be flush with bevel ofquill. See Figure 20.

Sprockets and ChainsOccasionally, sprockets and chainsneed to be replaced due to wear orwhen changing the gear ratio isnecessary.

WARNINGWhile in operation, the chain andsprockets will form a pinch point.They could cause SEVERE INJURYif a hand or piece of clothingshould become caught in them.Disconnect power source beforeperforming maintenance to chainand sprockets.

WARNINGWorn sprockets are very sharpand could cause SEVEREINJURY. Use extreme cautionwhenever removing sprockets.Use protective gloves to preventinjury.



WARNINGWhen removing the master linkclip, ALWAYS wear eyeprotection. The clip may causeSEVERE INJURY if it were to hitthe eyes.

Chain Removal

1. Disconnect power.

2. Remove rear panel assembly.

3. Remove chain cover panel.

4. Loosen idler shoulder bolt.

5. Locate “master” link in chain. Thislink is identified by a clip whichholds it in place. The clip, shown inFigure 23, may be removed by

placing a pliers over the open endof clip and link pin. Apply pressureto clip to release it from the chain.

6. The chain will now pull apart easily.Apply a small amount of oil to themaster link area if the chain iscorroded or hard to remove.

Sprocket Replacement

When sprockets become worn ordamaged, they must be replaced. Thefollowing outlines this procedure.

NOTE: Note location and

orientation of sprockets to theirshafts. They must be returned tothe same position.

Motor Sprocket

1. Loosen set screw. See Figure 24.

2. Apply small amount of oil to shaft.

3. Pull sprocket from shaft.



A

B

Figure 23. Removal of Master Link Clip

A

B

C

D

A. Motor Shaft Key C. Set Screw

B. Motor Shaft D. Motor Sprocket

Figure 24. Motor Sprocket Assembly

A. Pliers B. Master Link

Idler Sprocket

1. Loosen shoulder bolt. SeeFigure 25.

2. Remove shoulder bolt, idlersprocket, spacer, and threadedinsert.

NOTE: When replacing the idlersprocket, the threaded insert mayneed to be held in place with a flatscrewdriver.

Link Assembly Sprocket

If any looseness is noticed in the link,the sprocket, the shaft or the key, theymust be replaced. See Figure 26. Toremove the Link Sprocket Assembly:

1. Remove the rear panel, cover plate,and bearing support.

2. Loosen set screw and removesprocket from shaft.

3. Inspect shaft and key for signs ofwear. Replace the key and/or shaftif any looseness is noticed.

4. Inspect the set screw and key foreach sprocket. Replace set screwand key it if there are any signs ofdamage.

5. Align sprocket key slot with shaftkey and install sprocket.

6. Align sprockets using a straightedge. See Figure 27.



A

B

C

D

A. Shoulder Bolt C. Spacer

B. Idler Sprocket D. Threaded Insert

Figure 25. Idler Sprocket Assembly

A

B

C

D

A. Key C. Sprocket

B. Link D. Set Screw

Figure 26. Removing the Link Sprocket

CAUTIONImproper sprocket alignment willcause irreparable damage tosprockets and chain. Use astraight edge (such as a metalrule) to align the sprockets.

7. Tighten set screws.

8. Install chains. See “ChainInstallation/Adjustment” on thispage.

NOTE: Do not tighten idler sprocketcompletely. Idler sprocket must beloose to adjust chain tension.

Chain Installation/Adjustment

1. Inspect chain for wear and/ordamage. Replace chain asnecessary.

2. Thread chain over proper sprockets.

NOTE: Chain may need to have afew links removed to obtain properlength.

NOTE: Paint master link clip abright color prior to installing it.This will help to locate it in thefuture. Always use a new clip whenre-assembling chain.

3. Replace the master link and clip.



CORRECT SPROCKET ALIGNMENT

INCORRECT SPROCKET ALIGNMENT

Figure 27. Checking for Proper Sprocket Alignment

CAUTIONMake sure clip is COMPLETELYseated on master link pins. If clipcomes off, chain may come apart,possibly causing damage tomachine and loss of productcaused by machine malfunction.

4. Adjust chain tension by moving idlersprocket. The chain should deflectabout .25 inches (6.35mm) atpoints shown in Figure 278.

5. Tighten idler sprocket.

6. Install outer bearing support, cover,and rear panel.

Link AssemblyLocated at rear of feeder is the linkassembly which activates the agitatorpaddles. The link assembly must bedisassembled for most maintenance,to drive systems, or when installing adifferent eccentric. To disassemble orremove link assembly, do thefollowing:



Single DriveUnits

Dual DriveUnits

Check chaindeflection here



Figure 28. Location to Check Chain Deflection

1. Remove rear panel, cover panel,and outer bearing support.

2. Remove the two retaining clips thathold the link assembly to paddleshaft levers.

3. Remove chain from link sprocketassembly.

NOTE: During disassembly, be sureto note location of spacers on thelink assembly shaft. Whenreassembling the link assembly, thespacers must be placed in the samelocation or the drive chain will notbe properly aligned.

4. Remove link assembly sprocket asdescribed in “Link AssemblySprocket”, page 35.

5. Pull link assembly and shaft offlevers.

NOTE: Changing eccentric in linkassembly requires a large press.For more details on types ofeccentrics available and the size ofpress needed, contact yourCustomer Service Representative(see page 5 for details).

To install link assembly:

1. Slide link assembly and shaftthrough bearing.

2. Place link arm assembly overpaddle shaft levers as assembly isbeing slid toward frame and installNEW retaining clips.

3. Install link assembly sprocket asdescribed in “Link AssemblySprocket”, page 35.

4. Put chain on sprocket and adjustchain as outlined in “Sprockets andChains”, page 33.

5. Install bearing support, cover panel,and rear panel. Tighten idlersprocket.

Eccentric Changes

NOTE: Changing eccentric in linkassembly requires a large press.For more details on types ofeccentrics available and the size ofpress needed, contact yourCustomer Service Representative(see page 5 for details).



A

B

C

D

Figure 29. Removing Link Assembly

Changing the eccentrics, may increaseor decrease the agitation of the vinylhopper. To change the eccentrics dothe following:

1. Remove the link assembly. See LinkAssembly, page 37.

2. Remove retaining clip (Item A,Figure 30).

3. Remove eccentric from linkassembly.

4. Loosen set screw in eccentric andremove eccentric shaft fromeccentric. See Figure 30.

5. Install eccentric shaft in neweccentric and tighten set screw.See Figure 30.

6. Reverse procedure to installeccentric in link assembly andinstall link assembly on feeder.

Agitation PaddlesThe following procedure detailsagitation paddle removal:

1. Remove cover, side panels, helixand hopper, as described in “Panels,Helix and Hopper”, page 29.

2. Remove cover plate and outerbearing support.

3. Remove link assembly as describedin, “Link Assembly”, page 37.

4. Mark orientation of paddle ends tolever assemblies.



A

C

D

E

B

A. Retaining Clip D. Eccentric ShaftB. Link Assembly E. EccentricC. Set Screw

Figure 30. Replacing Eccentric

NOTE: Right and left paddles arenot the same. Each paddle has an“R” or an “L” on the back. Thisrefers to the right or left as you facethe feeder, from the nozzle side.

5. Remove lever assemblies.

6. Slide paddle toward rear bearinguntil shaft clears front bearing.Remove paddle assembly. Removesecond paddle in the same fashion.

The following procedure detailsagitation paddle installation:

1. Slide proper paddle through openingof rear bearing. Position front ofpaddle shaft in front bearing.

Position second paddle in similarfashion.

2. Install levers on paddle shaft ends.Make sure marks on levers alignwith those on shafts.

CAUTIONPaddles must be properly alignedor damage may result. If paddlesare not aligned properly, they mayhit motors causing damage topaddles and/or motors.

3. Install link assembly as described in“Link Assembly”, page 37.



Slide paddles toward

rear of feeder

Figure 31. Removal of Agitation Paddles

4. Install outer bearing support andcover plate. Secure with properhardware.

5. Install hopper, helix, side panels,and cover as described in “Panels,Helix and Hopper”, page 29.

Motor and Gear Reducer

DANGERIn 601 Series feeders, DO NOTuse any organic based solutionson or near the feeder. The use oforganic solutions may causeexplosions and fire.

The motor brushes are the only motorservice parts available for the motor. Ifa problem (other than worn brushes)

should arise with a motor or a gearreducer, the motor must be replaced.For details on a replacement motor orreducer contact your CustomerService Representative (see page 5for details).

DANGERDisconnect ALL power to feederbefore performing maintenance tomotor. This is a HIGH VOLTAGEarea and could cause SEVEREINJURY or DEATH. Maintenanceshould only be conducted byauthorized, trained personnel.



A

B

C

D

E

A . Upper motor mounting bolts

B. Lower motor mounting bolts

C. Motor

D. Side panel

E. Chain and sprockets

Figure 32. Removing the Motor and Reducer

Removal and Installation

1. Remove rear panel and side panel(next to motor).

2. Remove the nozzle, helix, andhopper described in “Panels, Helixand Hopper”, page 29.

3. Remove chain and drive sprocketfrom gear reducer shaft. Forinformation on chain and drivesprocket, see “Sprockets andChains”, page 33.

4. Remove the paddle next to themotor.

5. Disconnect motor power cord fromthe junction box.

NOTE: The junction box is locatedunder the feeder frame. The feedermust be placed on its side to gainaccess to the box. Remove screwsfrom top of box. Locate connectionfor motor and remove wire nuts. Slidewire out of junction box.

NOTE: Note wire routing throughframe to junction box.

6. When servicing feeders with DualDrives, it may be necessary toremove the junction box beforeremoving the right side motor.

7. Remove the two bolts securing thegear reducer to back of feederframe. See Figure 30.

8. Slide motor forward until shaftclears hole in feeder frame.

NOTE: The front paddle bearingmay have to be removed if itinterferes with the motor removal.Simply remove the two mountingbolts.

The motor can now be removed fromthe frame.

Reverse procedure to install the motorand gear reducer.

Motor Brush Replacement

1. Disconnect power to motor.

2. Remove hopper to gain access tomotor.



A

B

C

D

A. Brush C. Plug

B. Cap D. Motor

Figure 33. Replacing the Motor Brushes

3. Remove cap and plug with a largescrewdriver.

4. Replace brush, see Figure 33.

5. Install plug and cap.

6. Repeat procedure for remainingbrush.

7. Install hopper and reconnect powerto motor.

Touchpad Potentiometer

DANGERDisconnect power to controllerbefore performing anymaintenance. Controller containsitems of HIGH VOLTAGE. Theseitems can cause SEVERE INJURYor DEATH. Only trained andauthorized personnel shouldattempt maintenance to controller.

Setup Jumper

The setup jumper maintainspotentiometer mode when power isturned off. If jumper is in “ON” position,motor remains off when unit ispowered up requiring the operator tomanually enable operation. If jumper isin the “LAST” position, the unit will bein the last setting unit was in when thepower was turned off. See Figure 34.

To change jumper setting:

1. Disconnect all power to controller.

2. Loosen the four screws and opencover.

3. Move jumper to desired location.

4. Close cover and tighten the fourscrews.

CAUTIONMake sure cover gasket isproperly sealed when cover istightened down. Any moisture inbox could damage componentsinside.

Chip Switch and Fuse

It is strongly recommended that theAccuRate Customer ServiceDepartment (see page 5 fordetails) be contacted before anyservice to the chip switch (Part #W-3800) or fuse is performed.

Lubrication

DANGERDO NOT use any organic basedsolutions or lubricants on or near601 Series feeders used to feedPotassium Permanganate(K

2MnO

4). Potassium

Permanganate is highly reactivewith organic solutions and maycause explosions and fire.

Lubrication is important in keepingyour feeder running smoothly. Refer to“Preventive Maintenance Schedule”,page 47, for lubrication schedule.





Jumper in top locationcontrol will power upwith feeder turned "OFF". Thisrequires the operator to manuallyenable operation.

Jumper in bottom locationcontrol will power up in samecondition as when powered down

Chip Switch

F2

R1

R2

NEUT

LINE

ON

Last

Figure 34. Changing the Setup Jumper

WARNINGALWAYS disconnect power tofeeder before lubricating feedercomponents. The areas wherelubrication is being performedcontain items that could causeSEVERE INJURY. NEVERperform lubrication when feederis running.

Chains

To lubricate chain:

1. Remove rear panel and cover plate.

2. Lightly oil entire chain. DO NOTuses organic based oils on 601Series feeders.

3. Install cover plate and rear panel.

Cleaning and SanitizingIf your feeder is used in a food or dairyapplication, the unit must be cleanedand sanitized regularly. Frequency ofcleaning and sanitizing depends onproduct and local laws andregulations.

NOTE: These instructions are onlyguidelines. Contact your localhealth inspector for specific lawsand regulations for your area andprocess.

DANGERThe use of water and/or cleaningsolutions increases the risk ofelectrical shock. Disconnect andlock out all power sources to unitprior to cleaning.

A typical cleaning and sanitizingprocedure is usually done in thefollowing order:

• RINSE - Remove any productresidual.

• CLEAN - Use a detergentsolution to clean all surfaces ofunit.

• RINSE - Remove all detergentsolution.

• SANITIZE - Use a sanitizingsolution to sanitize unit.



Seals

Figure 35. Quill and Drive Shaft Seals

The following information explains theprevious mentioned steps.

Rinsing

Use water to completely remove anyproduct that may have built up inhopper or exterior of the unit. The unitmust also be rinsed of all detergentsolutions prior to sanitizing.

Cleaning

DANGERDO NOT use any organic basedsolutions or lubricants on or near601 Series feeders used to feedPotassium Permanganate(K

2MnO

4). Potassium

Permanganate is highly reactivewith organic solutions and maycause explosions and fire.

To clean your feeder, remove helix,nozzle and hopper as outlined in“Disassembly of Panels, Helix andHopper”, page 29.

After the hopper has been removed,do the following:

• The hopper, helix, and nozzlemust only be cleaned with mildsoap and water. Limited use ofmineral sprits is approved. DONOT uses mineral sprits on601 Series feeders.

• The seals must be removed fromthe quill and cleaned. If sealsshow any signs of wear, replacethem. See Figure 35 for locationof seals.

• Wipe down remainder of unitwith cleaning solution.

Sanitizing

While unit is disassembled, sanitize allparts using an approved sanitizingsolution. Contact your local healthauthority for information on suitablesanitizing agents.

CAUTIONSanitizing agents may be corrosiveto hopper and/or seals. Select asanitizing agent that is compatiblewith these materials. Limitexposure of these items to reduceeffects agents may have.



Preventive Maintenance ScheduleIMF60000RV110596

The following table outlines the maintenance schedule that you should follow tokeep your feeder in proper working order.

The numbers in the table represent different tasks. For a complete description ofthe task, refer to the “Maintenance” section of this manual starting on page 29.

Number Task

1 Adjust

2 Lubricate (see “Lubrication” section on page 43for instructions)

3 Inspect for wear or other signs of malfunction

4 Replace

Item Daily Weekly Monthly 3 Months 6 Months Annually

Chain 1, 2, & 3

Sprockets 1 & 3

Motor 3

GearReducer

3

Helix 3



DANGERDO NOT use any organic basedsolutions or lubricants on or near601 Series feeders used to feedPotassium Permanganate (K

2MnO

4).

Potassium Permanganate is highlyreactive with organic solutions andmay cause explosions and fire.

Item Daily Weekly Monthly 3 Months 6 Months Annually

Nozzle 1 & 3

Hopper 3

HopperExtensionFilter

3 4

DriveShaft

3

Seals 3 4

Quill 3

Bearings&Bushings

3

Nuts &Bolts

1 & 3

Keyways 3

EccentricShaft

3



Troubleshooting

IMF60000RV110596

This is a guide to check problems that might arise under normal operation.Consult the manual for instructions regarding the action to be taken. FOLLOWALL SAFETY GUIDELINES LISTED IN THIS MANUAL.

Problem Cause Solution

Feederdoesn’t run

Blown fuse - AC line Replace the fuse

Poor wiring connectionsof amphenols or terminalblock

Tighten connections & resolderleads if necessary

Incorrect wiring Check schematic & rewire ifnecessary

Improper analog input Correct source signal




Feeder runs,but notcorrectly

Runs backwards Switch motor armature leads atthe terminal block or motor

Runs wide open Check the potentiometer leadsposition

Maximum speed potentiometerblown - replace the board

Improper analog input - bad4-20mA or 0-10VDC signalcoming from your processcontroller

Partial potentiometeradjustment

*Bad potentiometer - checkresistance through full range0-5000 ohms, replace if it failsthe test

Motor surges AC line voltage varies - installline conditioner

*DC output voltage too high±10% adjust max trimpot

Motor brushes are bad - replace

Feederstalls

Flow restrictions Remove restrictions from nozzleadapter



* Contact your Customer Service Department for assistance. See page 5 fordetails.


Feederstalls(continued)

Helix and nozzle notflush at the dischargeend

Reposition the helix and thenozzle until they are flush

Foreign objects lodgedin helix

Turn off power and remove theforeign objects then restart thefeeder

Pellets jammed in helix *Increase the nozzle diameter ordecrease the helix diameter toprovide more clearance andeliminate the pinch point

Product buildup insidethe nozzle

*Review helix and nozzlecombination for your applicationchange if needed

* Contact your Customer Service Department for assistance. See page 5 fordetails.



Parts Lists

IMF60000RV110596

The pages following the index containthe information you need to orderreplacement parts. Locate the part youneed to order and its part number.Then contact your CustomerService Representative to placeyour order. See page 5 for details.

NOTE: Some items may have aminimum order quantity. Theseitems are marked by an asterisk (*).



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