AEC OFE Blender User Manual

$30.

Operation and Installation Manual

OFE Series

Loss-In-Weight Color Feeders for Extrusion

Important! Read Carefully Before Attempting to Install or Operate Equipment

00

Part No. A0553649 Revision 3 Bulletin No. HR6-650B.3

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.

Parts and Service Department

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering
design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone
or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list
is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.

For immediate assistance, please contact:

• North, Central and South America, 8am – 5pm CST [phone] for drying, conveying, heating and cooli

ng
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America

Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the
name of the sales representative nearest you.

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages
including drawings; equipment, labor, and construction materials; and union or non-union installations.

For assistance with your sales or system contracting needs please Call:

North, Central and South America [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

Write down your unit serial number(s) ________________ ________________
here for future reference ________________ ________________

________________ ________________
________________ ________________
________________ ________________
________________ ________________
________________ ________________
________________ ________________
________________ ________________

AEC is committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual

are subject to change without notice.

© Copyright AEC, Inc. 2012

All rights reserved.

Part No. A0553649

Page 2 OFE Series Weight Loss Feeders

Effective 12/12/12

Bulletin No. HR6-650B.3

Table of Contents

1 General Information .................................................9

1-1 Models Covered
1-2 Equipment Function
1-3 Necessary Documents
1-4 Standard Features
1-5 Options

2 Safety.......................................................................12

2-1 Work Rules
2-2 Tools and Equipment Needed
2-3 Mechanical Installation
2-4 Safety Considerations
2-5 General Responsibility
2-6 Operator Responsibility
2-7 Maintenance Responsibility
2-8 Safety

3 Shipping Information .............................................20

3-1 Unpacking and Inspection
3-2 In the Event of Shipping Damages
3-3 If the Shipment is Not Complete
3-4 If the Shipment is Not Correct
3-5 Returns

4 Installation...............................................................22

4-1 Setup
4-2 Unit Calibration and Setup
4-3 Diagnostics
4-4 OFE Menu Structure

OFE Series Weight Loss Feeders Page 3

Table of Contents

5 Startup, Shutdown, and Operation.......................27

5-1 Starting and Operating the Unit

6 Maintenance ............................................................29

6-1 Work Rules
6-2 Maintaining Feeders
6-3 Controller Setup
6-4 Mechanical
6-5 Electrical
6-6 Pneumatic System Maintenance

7 Troubleshooting .....................................................34

7-1 If Unit Fails to Operate
7-2 If Unit Stops Intermittently
7-3 If Unit is Inaccurate
7-4 If Drive Motor Burns Out or Blows Fuses

8 OFE Feeder Options...............................................36

9 Spare Parts List ......................................................37

10 Technical Assistance.............................................38

10-1 Contact Information
10-2 Returned Material Policy
10-3 Warranty

11 Safety Tag Information...........................................42

11-1 OFE Series Safety Tags
11-2 OFE Series Identification (Serial Number) Tag

Page 4 OFE Series Weight Loss Feeders

Safety Considerations

AEC OFE Series feeders are designed to provide safe and reliable operation when installed and
operated within design specifications and national and local safety codes.

To avoid possible injury or equipment damage when installing or operating this equipment,
always use good judgment and follow these safe practices:

; Follow all SAFETY CODES.
; Keep fingers away from slide gates, augers, cleanouts, and calibration hatches.

Because automatic operation may start unexpectedly, A PINCH HAZARD
CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE
POWER IS ON.

; Wear SAFETY GLASSES and WORK GLOVES.
; Use care when installing, operating or servicing this unit.
; Disconnect and/or lock out power before servicing or maintaining the blender.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

; Disconnect and lock out power and compressed air before attempting to clean out

an auger and slide gate area.

; NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE

AREA.

; Make sure the blender and components are properly GROUNDED before you

switch on power.

; Do not jump or bypass any electrical safety control.
; Do not jump or bypass any pneumatic safety control.
; Do not restore power until you remove all tools, test equipment, etc. and until the

blender and related equipment are fully assembled.

; Only PROPERLY TRAINED personnel familiar with the warnings and

instructions in this manual should work on this equipment.

OFE Series Weight Loss Feeders Page 5

AEC

“OFE” Series

Loss-In-Weight Color Feeders for Extrusion

This Feeder is manufactured by ACS, Inc.:

ACS, Inc.

801 AEC Drive

Wood Dale, IL 60191

Phone: [phone]

Fax: [phone]

The equipment is distributed in Europe by our European facility:

ACS-EUROPE

Daniels Industrial Estate

BATH ROAD

Stroud, Gloucestershire, England

GL5 3TJ

Phone: [phone]

Fax: [phone]

Page 6 OFE Series Weight Loss Feeders

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Allowable voltage fluctuation: +/- 10%

9. Allowable frequency fluctuation: Continuous +/- 1%
Intermittent +/- 2%

10. Nominal supply voltage: 120/1/60 or 220/1/50 (Verify on serial number tag)

11. Earth ground type: TN (system has one point directly earthed through a

protective conductor)

12. Power supply should include a neutral power connection.

13. Over-current protection is supplied to the Feeder, but additional protection should be

supplied by the user.

14. The plug on the power cord serves as the electrical disconnect device.

15. Feeder is not equipped with local lighting.

16. Functional identification

17. Feeder is equipped with a CE mark

18. Feeder is supplied with an operating manual in the language of the destination country.

19. Cable support may be required for power cord, depending on final installation.

20. No one is required to be in the interior of the electrical enclosure during the normal

operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.

21. Doors can be opened with a screwdriver, but no keys are required.

22. Two-hand control is not required or provided.

23. All Feeders should be moved around and set in a place with a lift truck or equivalent.

24. There are no frequent repetitive cycles that require manual control⎯repetitive functions

are automatic while the conveying system is operating.

25. An inspection report detailing the functional test is included with the feeder.

26. The machine is not equipped with cableless controls.

27. Color-coded (harmonized) power cord is sufficient for proper installation.

OFE Series Weight Loss Feeders Page 7

Charts and Figures

1

OFE Series Weight Loss Feeder Illustration 11

2

OFE Series Customer Recommended Spare Parts List 37

Page 8 OFE Series Weight Loss Feeders

1 General Information

1-1 Models Covered

This manual covers all AEC OFE Series feeder models.

1-2 Equipment Function

Modern plastics processing demands the addition of precisely metered components.
Your OFE Series auto adjust colorant and additive feeder is a self adjusting, loss in
weight calibrated feeder designed to meter a precise preset rate of free flowing
pelletized additive into the extruder throat. The unit is equipped with an inductive
proximity switch to sense the extruder screw RPM to provide slaved in operation.

The unit is self-adjusting to compensate for varying bulk densities, different pellet cuts,
etc. It will save colorants that result from operator calibration errors, and varying bulk
densities of pellet additives.

1-3 Necessary Documents

The items listed below are required for installation, operation, and maintenance of AEC
OFE Series feeding systems. Additional copies are available from AEC, Inc.
Familiarize the appropriate personnel with these documents:

; This manual.
; The Customer Parts List.
; Operation and Installation manuals for accessories and options selected by the

customer, where installed.

1-4 Standard Features

All OFE Series loss-in-weight extrusion additive feeders are designed to feed high cost
additives and come standard with these features:

• Precision 1/10% span accurate cantilever load cell weighing system

• Alluminum and mild steel contact surfaces

• Surge hopper with conical reload valve

• Operator control panel with LCD display

OFE Series Weight Loss Feeders Page 9

• RS-485 communications port

• Parallel printer port connection

• Extruder following circuit

• Field mount proximity switch

• Square mounting flange

• 3” OD discharge opening

• 115/1/60 or 220/1/50 supply voltage

• Feeder housings with drain tube

• Hopper lid arranged for AEC SRC Series receivers and loaders. Hopper lid

may also be cut for customer-supplied non-AEC loading hoppers at no
additional charge, provided detailed drawings are provided with order.

1-5 Options

• RCP – RS-485 remote control panel with 10 ft. cable, 100 ft. maximum

distance (consult factory for longer distance)

• Supply hopper lids cut for non-AEC customer-supplied vacuum receivers or

loaders, per hopper

• Includes cutout and bolthole pattern only – adapters supplied at an

additional charge

Page 10 OFE Series Weight Loss Feeders

Figure 1

OFE Series Weight Loss Feeder Illustration

Top view

Front view

OFE Series Weight Loss Feeders Page 11

2 Safety

2-1 Work Rules

Install, operate, and maintain this equipment according to applicable work and safety
codes for your location. This includes OSHA, CE, NEC, CSA, SPI, and many other
local, national, and international regulations. Obey these specific work rules:

 Read and follow the instructions in this manual before

installing, operating, or maintaining any equipment.
Additional copies are available from AEC, Inc.

 Only qualified persons should work on, or with, this

equipment.

 Work only with approved tools and devices.

 Disconnect and lock out power while working on this

equipment.

2-2 Tools and Equipment Needed

You’ll need the following:

• Hand tools

• Fork lift or overhead lift

• Wire, conduit, and fittings for wiring runs (if receptacle is not

already in place)

• Mounting bolts with nuts and washers

2-3 Mechanical Installation

OFE Series Feeders may be mounted on the machine, a stand, or a
mezzanine. Be sure it is securely attached and additional bracing
is used if necessary. The sections on the following pages explain
general installation rules.

Read manual thoroughly before installing the
OFE feeder.

Use approved safety straps or chains to lift the
feeder at the marked lifting points.

Page 12 OFE Series Weight Loss Feeders

2-4 Safety Considerations

The terms NOTICE, CAUTION, WARNING, and DANGER
have specific meanings in this manual. See Section 11 for a

complete list of specific safety warning information.

A NOTICE is used to indicate a statement of company policy
directly or indirectly related to the safety of personnel or protection
of property.

A CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.

A WARNING indicates a potentially hazardous situation which, if
not avoided could result in death or serious injury.

A DANGER indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury. This word will
be limited to the most serious situation(s).

The term IMPORTANT emphasizes areas where equipment
damage could result, or provides additional information to make a
step or procedure easier to understand. Disregarding information
marked IMPORTANT would not be likely to cause personal
injury.

REPORTING A SAFETY DEFECT

NOTE: If you believe that your equipment has a defect which could cause

injury, you should immediately discontinue its use and inform
AEC, Inc., at our address listed in this manual.

The principle factors which can result in injury are:

1. Failure to follow proper operating and clean-out

procedures, i.e. lockout/tagout.

2. Failure to maintain a clean and safe working environment.

OFE Series Weight Loss Feeders Page 13

2-5 General Responsibility

NO MATTER WHO YOU ARE…

Safety is important. Owners, operators, and maintenance
personnel must realize that every day, safety is a vital aspect of
their jobs.

If your main concern is loss of productivity, remember this:

Production is always affected in a negative way following an
accident. The following are some of the reasons which can affect

your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Down-time

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.

2-6 Operator Responsibility

The operator’s responsibility does not end with efficient
production. The operator usually has the most daily contact with
the feeder 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.

Page 14 OFE Series Weight Loss Feeders

REMEMBER:

ONLY YOU can make safety work for you by constantly thinking
about what is safe and what is not. It is often the “just once” that
an operator reaches into the feeder to remove material and it results
in serious injury.

Learn and always use safe operation. Cooperate with co-workers
to promote safe practices. Immediately report any potentially
dangerous situation to your supervisor or appropriate person.

• 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

OFE Series Weight Loss Feeders Page 15

• 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 the feeder. In addition,
cover or tie back long hair.

• 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.

2-7 Maintenance Responsibility

Safety is essential to the good health of both operator and machine.
If you are a maintenance worker, you must make safety a priority
in order to effectively repair and maintain equipment.

BEFORE REMOVING, ADJUSTING, OR REPLACING
PARTS ON A MACHINE, REMEMBER TO DO THE
FOLLOWING:

• TURN OFF all air and electric supplies and all accessory

equipment at the machine.

• DISCONNECT AND LOCK OUT electrical and pneumatic

power, and attach warning tags to the disconnect switch and air
shutoff valve.

When you need to perform maintenance or repair work on the
feeder above floor level, use a solid platform or a hydraulic
elevator. If there is a permanently installed catwalk around your
feeder, use it. The work platform should have secure footing and a
place for tools and parts. DO NOT climb on 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.

Page 16 OFE Series Weight Loss Feeders

2-8 Safety

2-8-1 Description and Objectives

Be sure that all non-current carrying parts of electrical apparatus,
electrical component enclosures, and the feeder frame are correctly
connected to earth ground with an electrical conductor that
complies with current codes. Install in accordance with national
and local codes, which apply.

When you have completed the repair or maintenance procedure,
check your work, remove your tools, rigging, and handling
equipment.

Do not restore power to the feeder until all persons are clear of the
area. DO NOT start and run the feeder until you are sure all parts
are functioning correctly.

BEFORE you turn the feeder over to the operator for production,
verify all system enclosure panels, guards and safety devices are in
place and functioning properly.

This section includes information on safety devices and procedures that are
inherent to the OFE Series 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:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety devices.

2-8-2 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 the manufacture of automated equipment. The
Occupational Safety and Health Administration (OSHA) and the Joint

OFE Series Weight Loss Feeders Page 17

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
OFE Series 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.

2-8-3 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.

2-8-4 Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety
devices that are utilized on this equipment are primarily concerned with the
pneumatics and 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, disconnect
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.

WARNING! Always disconnect and lockout all electrical power and pneumatic

(i.e. compressed air) sources prior to servicing or cleaning any
OFE Series Feeder. Failure to do so may result in serious injury.

At no time must anyone remove the lockout or reconnect the twist

plug, other than the person who installed the lockout or who

unplugged the twist plug.

2-8-5 Lock-Outs, Plugs, and Other Safety Devices

The OFE Series Feeder utilizes several types of safety devices.

The Line Cord Plug

This line cord plug allows the operator or maintenance personnel
to unplug the feeder from its power source and tag it out. This plug

Page 18 OFE Series Weight Loss Feeders

WARNING!

may be tagged with any number of approved electrical lockout
tags. These tags are available at most electrical supply stores.

Disconnect both of these items to ensure optimum maintenance
personnel safety when cleaning or servicing this equipment.

-Notes-

OFE Series Weight Loss Feeders Page 19

3 Shipping Information

3-1 Unpacking and Inspection

You should inspect your AEC OFE Series weight loss feeder for possible shipping
damage. If the container and packing materials are in re-usable condition, save them for
reshipment if necessary.

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 case of breakage, damage, shortage, or incorrect shipment, refer to the following
sections.

3-2 In the Event of Shipping Damages

Important!

According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of

shipment. The Carrier then assumes full responsibility of the
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 to AEC, Inc. before the
transportation company inspection and authorization.

; File a claim against 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 AEC, Inc. regarding your wish for replacement and to obtain an

RMA (return material authorization) number.

Parcel Post Shipment

; Notify AEC, Inc. at once in writing, giving details of the loss or damage.

This information is required for filing a claim with our insurance
company.

Page 20 OFE Series Weight Loss Feeders

; Hold the damaged goods with the container and packing materials for

possible inspection by postal authorities.

United Parcel Service

; Contact your local UPS office regarding damage and insurance claims.
; Retain the container and packing.
; Notify AEC, Inc. at once.

3-3 If the Shipment is Not Complete

Check the packing list. The apparent shortage may be intentional. Back-ordered items
are noted on the packing list. You should have:

; AEC OFE Series weight loss feeder
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items
during unpacking. Determine that the item was not inadvertently taken from the area
before you checked in the shipment. Notify AEC, Inc. immediately of the shortage.

3-4 If the Shipment is Not Correct

If the shipment is not what you ordered, contact AEC, Inc. immediately. Include the
order number and item. Hold the items until you receive shipping instructions.

3-5 Returns

Important!

Do not return any damaged or incorrect items

until you receive shipping instructions from AEC, Inc.

OFE Series Weight Loss Feeders Page 21

4 Installation

4-1 Setup

General Setup and Installation

; Install the OFE feeder on the machine throat. Ensure that the unit is mounted

horizontally and not angled. Check the installation to ensure that the feeder
can easily be emptied, and that the extruder supply hopper is not touching the
weighed colorant hopper. Support the feeder so that it is not subject to
processing machine vibrations, etc. that can affect the accuracy of the unit.

; Connect the 110V power to the panel. Ensure that the circuit powering the

control is clean, and does not also power other equipment that draw high
current loads. The control circuit is provided with a high quality isolated
power supply; however, it should not be subject to voltage fluctuations other
than normal conditions.

; Mount the proximity switch on the rear of the extruder gearbox, and install a

bolt or other similar metal pickup on the rear hub of the extruder screw.
Adjust the proximity switch so that it is reading the pickup. This is done by
adjusting the gap between the proximity switch and the pick-up and adjusting
the sensitivity adjustment until the LED light on the proximity switch lights
up each time the pick-up passes. Wire the proximity switch into the OFE
control panel to the appropriate terminal (check the enclosed drawing).

; Install the appropriate vacuum loading equipment on the virgin supply hopper.

This can either be provided at extra charge by AEC or an existing system can
be used.

Loading Configurations and Options

; The OFE feeder will be supplied with an upper storage hopper with an air

operated conical valve. The vacuum loader will simply be mounted on top of
the upper hopper, and will use its own level control system.

Page 22 OFE Series Weight Loss Feeders

4-2 Unit Calibration and Setup

Scale Calibration

; Empty the weigh hopper.
; From the Startup menu, press

3, 1, 1, 1. This will take you into the Setup

menu, Feeder Setup section, and Scale Calibration section.

; Make sure the weigh hopper is empty, then follow the menu prompts to

complete the calibration. The menu will tell you when to place the calibration
weight on the load cell supported weigh hopper, and to key in the weight of
the calibration weight (any weight will work, as long as the precise weight is
known).

; If you wish to check the weigh hopper, after the calibration is done, enter the

Diagnostics menu to Scale Readout. Replace the weight on the hopper, and
check to see if the weight is the same. It should be within a few hundredths of
a pound. Press BACKUP to return to the Startup menu.

Auger Calibration

After the scale has been calibrated, follow the steps below to calibrate the metering
auger. This is necessary on the first initial calibration, to avoid overfeeding material
until the unit learns the proper feed rate (set from the Setup menu).

; Starting from the Startup menu, press 3, 1, 1, 2. This will take you to the

Setup menu, Auger Calibration section.

; Unsnap the sample port cover on the auger feed housing, and place a container

under the auger.

; Follow the menu prompts and run the calibration routine. The auger will be

automatically calibrated, and will show the metering range on the particular
material.

; Dump the metered material back into the weigh hopper.
; The screen prompt will indicate when calibration is complete.

IMPORTANT!

OFE Series Weight Loss Feeders Page 23

If you do not remove the sample port cover, additive pellets

are fed directly into the machine throat (your choice).

4-3 Diagnostics

Scale Diagnostics

The Diagnostics menu allows reading of the A/D scale. This is the analog to digital
conversion that the computer needs to read the level of loading of the load cell.

The standard resolution of the A/D load cell is 4,095 increments over the span of the
load cell.

Checking these A/D readings with known weights will diagnose any problems with the
weighing system, such as non-linearity, damaged load cells, binding, etc.

Auger Diagnostics

The Auger Diagnostics menu allows manual speed adjustment of the auger drive
motor. Simply follow the menu prompts to raise or lower the auger speed.

Setup Menu

The Setup menu allows adjustment of the software program to conform with the
particular configuration of each system as the application requires.

Each system is supplied with an individual configuration sheet to be used with that unit.
Setups are stored in the battery-backed RAM memory, and should not need resetting.

If an OFE feeder is connected to a host computer system, you may need to adjust or
update the unit ID number and communications baud rate before the unit can
communicate. Consult the factory for proper ID and baud rate settings.

Page 24 OFE Series Weight Loss Feeders

4-4 OFE Menu Structure

Main Menu

- Startup

- Recipes

- Setup & Diagnostics

- Inventory

- Printer (optional)

Main Menu

1) Startup

2) Recipes

3) Setup & Diagnostics

4) Inventory

5) Printer

Startup

- Press 'Start'

Recipes Menu

- Set Flow Rate

Setup & Diagnostics

- Setup

- Diagnostics

Inventory Menu

- Press to See

Printer Menu (optional)

- Test Print

- Set Job Number

- Set Print Interval

- Print Data

Setup Menu

- Feeders

- System

- Factory

Diagnostics Menu

- Scale Readouts

- Auger/Pickups

- Communications

- Alarm Log

- Extruder Information

Feeders Setup Menu

- Calibrate Scale

- Calibrate Auger

- Set Hopper Size

- Set Learn Cycle

- Set Gearbox Ratio

System Setup Menu

- Auto/Manual Start

- Set Alarm Action

- Communications

- Set Time & Date

Factory Setup Menu

- English/Metric

- Number of Feeders

- User Password

- Set Max. Motor RPM

Communications Menu

- Set Speed

- Set ID

Recipes Menu

1) Set Flow Rate

Setup & Diagnostics

1) Setup

2) Diagnostics

Setup Menu

1) Feeders

2) System

3) Factory

OFE Series Weight Loss Feeders Page 25

Feeders Menu

1) Calibrate Scale

2) Calibrate Auger

3) Set Hopper Size

4) Set Learn Cycles

5) Set Gearbox Ratio

System Setup Menu

1) Auto/Manual Start

2) Set Alarm Action

3) Communications

4) Set Time/Date

Communications Menu

1) Set Speed

2) Set ID

Factory Setup Menu

1) English/Metric Display

2) Number of Color Feeders

3) User Password

4) Set Maximum Motor RPM

Diagnostics Menu

1) Scale Readouts

2) Auger/Pickups

3) Communications

4) Alarm Log

5) Extruder Information

Inventory Menu

Printer Menu

1) Test Print

2) Set Job Number

3) Set Print Interval

4) Print Data

Page 26 OFE Series Weight Loss Feeders

5 Startup, Shutdown, and Operation

5-1 Starting and Operating The Unit

After the initial scale calibration, auger calibration, and setup items have been
completed and entered (one time only after installation), the unit is ready to start.

1. Start the extruder and bring up to production rate and gauge.

2. After the extruder is running at production speed, set in the running rate you

want on the feeder by pressing 2 on the keypad to enter the Recipe menu.

3. Press START to enter the feeder meter rate you want, then press ENTER to

enter the rate into computer memory.

4. Press the BACKUP key to return to the Startup menu.

5. Press 1 to start the unit.

6. If the inventory is not reading 0, press the BACKUP key to return to the

Startup menu, press 4 to enter the Inventory menu, then press CLEAR to
clear the inventory. Press BACKUP to return to the Startup menu, then press

1 to bring up the display.

Note: The control is multi-tasking. This means if the unit is running, other menus, such as

Inventory or Recipe, can be entered and changed while the unit is still running.
Then when it is restarted, by pressing 1 from the startup menu, the new changes
will take place and reset the unit.

OFE Operation (Automatic Mode)

The OFE control will increase the voltage output to the DC gear motor driving the
additive metering screw, until the actual metering rate matches the target metering rate.

In the automatic mode, the feeder delivers material at the rate set in by the operator.
The extruder screw speed is continuously monitored via the proximity switch mounted
on the back of the extruder screw. Once the extruder starts running at a constant speed,
the control learns the screw speed and internally sets up a table to slave in the OFE
feeder metering screw to the extruder screw speed. The production rate extruder screw
speed will equal the preset rate of the OFE feeder. Once this OFE feeder rate to the
extruder screw speed relationship table is internally established, then from this point
onwards, if the extruder screw speed is decreased or increased, the OFE feeder will
change its target rate accordingly.

Inventory is kept on the metered material, and can be downloaded to a data collection
network program.

OFE Series Weight Loss Feeders Page 27

If a communications network is installed, the OFE unit can also be used for production
and downtime tracking as the extruder speed can be continually down-loaded, date and
time stamped, and logged for production reports, etc.

OFE Operation (Manual Mode)

If the feeder is required to operate in manual mode (where it just runs a pre­programmed output rate when operating), do the following:

1. Turn the Reload switch on the control box from the AUTO position to the

2. Now using the speed pot dial on the SCR drive for the auger, set the desired

3. Provide some manual method such as a speed shutdown or voltage shutdown

IMPORTANT!

MANUAL position. (Doing so disconnects the power to the CPU board
completely and diverts the +24VDC to the Reload solenoid valve. This
ensures that the solenoid valve stays open permanently and material is
present all the time into the OFE hopper.)

speed as necessary to run the OFE in a strictly VOLUMETRIC mode.

circuit to shut the feeder off (if mounted on an extruder so the unit does not
feed color when the screw is stopped).

The feeder does not automatically follow the screw
or shut down when in the manual mode.

It meters at a preset rate when operating.

Page 28 OFE Series Weight Loss Feeders

6 Maintenance

6-1 Work Rules

The installation, operation, and maintenance of this equipment must follow all
applicable work and safety codes for the location where it is used. This may include,
but is not limited to, OSHA, CSA, NEC, SPI, and other local, national, and
international regulations. In addition, you must observe the following specific rules:

; Read and follow these instructions when installing, operating, and maintaining

your equipment. If the instructions become damaged or unreadable, you can
obtain additional copies from the Service Department at AEC, Inc.

; Only qualified people may work on or with this equipment.
; Work only with approved tools and devices.
; Turn off and lock out the power switch when maintaining or servicing your

blender system.

; Disconnect and lock out main power before servicing electrical equipment.

6-2 Maintaining Feeders

AEC feeders need periodic maintenance to provide long dependable service. Check
these elements regularly:

• Maintain proper air pressure and drain water from trap assembly on regulator – as

required.

• Periodically lubricate slide gate rails.

WARNING!

Always remove plug and disconnect power before servicing
blender.

Always read operating manual before operating or servicing
blender.

OFE Series Weight Loss Feeders Page 29

6-3 Controller Setup

This section describes the proper setup of the OFE Feeder control parameters. These
parameters are operator changeable; however, these items should only require setup
during the initial installation. Only authorized personnel should change them. For
security reasons, the menu that is used to access these parameters is password
protected.

Many of the variables and setup parameters have been preset at the factory and do not
need to be changed. However, this section of the manual will address all of the setup
parameters that were available at the time of printing. The purpose of this is to
familiarize the reader with all the setup parameters and their usage.

6-4 Mechanical

The mechanical design of the feeder is very simple and very little maintenance is
required. The only moving parts are the reload hopper dump valve. The following
maintenance is suggested:

Daily

• Inspect feeder for any loose parts-tighten them immediately.

Monthy

• Inspect air regulator and air safety circuits, if equipped.

• Recalibrate feeder only if necessary.

Page 30 OFE Series Weight Loss Feeders

6-5 Electrical

6-5-1 Description and Objectives

This section is designed to give the operator an overview of the electrical system
that controls the OFE Feeder system. Since the control panel is a self-contained
pluggable item, seldom will a maintenance person be required to enter the
control panel. For purposes of understanding the system, it is advisable that the
maintenance personnel be familiar with not only the internal workings of the
control panel, but also with the input and output signals to the unit.

This section includes the following:

• Internal components of the control panel

• Input signal to the control panel

• Output signals from the control panel

6-5-2 Internal Components of the Control Panel

Note: See Section for complete electrical schematics.

This section describes the internal components of the OFE Feeder control panel.
It is not the intent of this section to completely familiarize the reader with the
details on industrial control panel construction or standards, but simply to
familiarize the reader with the major components inside the control panel.

The customer must supply 120/1/50 or 60 (or 220/1/50 or 60) via wires L1 & L2
(N). Please insure that the earth ground connection is properly connected to an
established earth ground.

“Power on” is indicated by a lighted on/off switch.
Audible alarm horn alerts operator to feeder fault.

6-5-3 Input Signals to Programmable Controller

The OFE feeder has two main input signals that it uses from the blending
process: the extruder proximity switch signal and the weigh hopper load cells.
This, of course, does not include the operator touchscreen input.

Load cells require +5 VDC to operate. This is known as the load cell’s excitation
voltage.

OFE Series Weight Loss Feeders Page 31

6-5-4 Output Signals from Programmable Controller

The OFE Feeder uses several output control signals to control the process. All of these
are very similar in nature, the first of which is the auger m otor control.

The auger motor outputs are driven from a control output from the controller.

Each OFE Feeder includes an auxiliary customer alarm output. This dry contact can be
used to switch a remote alarm signal.

The customer alarm output is provided to actuate or energize a variety of alarm horns,
buzzers, strobe lights, and beacons. These are normally provided by the customer, and
care will have to be exercised not to exceed the maximum current draw (3 amp
maximum). The contacts will close whenever the control detects a f ault that will
somehow inhibit the blending system from properly blending the material.

Note: The customer alarm contact is open if the panel control power is turned

off.
This contact is for use with a customer supplied alarm device as described
above.
The alarm contact has a maximum load of 3 amps.

Page 32 OFE Series Weight Loss Feeders

6-6 Pneumatic System Maintenance

The OFE Feeder uses plant-supplied compressed air to operate the reload valve on the
surge hopper.

It is the user’s responsibility to provide CLEAN AND DRY air. The air supply should be
filtered through a 5 micron air filter and have a water separator installed. Oil should not
be used unless air dryers are installed on the compressed air supply.

Important! Dirty air can affect accuracy, result in poor performance

and cause injury. Provide a 5-micron air filter on the air
supply to the blender and be sure excess oil is removed.

DRY 60 psi COMPRESSED AIR

CUSTOMER- SUPPLIED COMPRE SSED AIR COMPONENTS

AEC provides all pneumatic lines on the feeder piped to a single ¼” NPT standard pipe
thread fitting.

5 MICRON

FILTER

LUBRICATOR

PR ES SUR E

REGU LATOR

OFE FEEDER

OS/OA BLENDER

OFE Series Weight Loss Feeders Page 33

7 Troubleshooting

Note: Direct any questions you may have concerning our equipment to our office.

7-1 If the Unit Fails to Operate

; Check fuse.
; Check main power.

7-2 If the Unit Stops Intermittently

; Check for loose connection.
; Check the motor speed control.
; Check the proximity switch on the extruder screw to ensure it is reading the

screw turns consistently.

7-3 If the Unit is Inaccurate

; Check auger drive motor pickup in Diagnostics.
; Check weigh hopper for binding or overfill.
; Check air cylinder in reload hopper (if applicable).
; Check auger for stalling. This will indicate a bent auger, bad gearbox, or drive

control.

; Check the A/D load cell in Diagnostics to ensure that the load cell is not

damaged and is linear. Linearity can be checked by adding several weights of
the same weight to the weigh hopper and checking to see that the A/D number
changes the same for each weight (AEC recommends using large washers of the
same size). If the A/D number is varying quite a bit, it will indicate that the load
cell has been sprung or overloaded. It will have to be replaced.

CAUTION!

Use care when cleaning the unit, or it can become damaged.

DO NOT PULL ON THE WEIGH HOPPER!

Page 34 OFE Series Weight Loss Feeders

; Check to see that the additive pellets are feeding consistently out of the weigh

hopper and not bridging occasionally in the hopper discharge throat. Consult the
factory if this is the case. We do offer a larger opening hopper (up to 21/2
inches). The feeder is designed for virgin pellet color concentrate. IT IS NOT

DESIGNED FOR REGRIND MATERIALS.

; Check the extruder screw speed pick-up proximity switch to ensure that it is

reading the extruder screw revolutions accurately.

7-4 If the Drive Motor Burns Out or Blows Fuses

; Check motor speed. Unit is probably running too slow. Change gear reducer to

higher ratio unit.

; Check auger to housing clearance, and if pellets are binding auger, consult

factory. Check auger for straightness. Sometimes the operators will let the drive
hang off the auger without removing it fully from the housing. This will bend
the auger. Bent augers are not covered under warranty.

; Check input voltage and wiring size to see if a low voltage situation exists.

Quite often the feeder and 110V loading systems are wired into the same outlet.
The voltage will check out at 120V when there is no load. Check the voltage
when all the units are operating at the same time. It will sometimes drop 20
percent or more. This indicates that the wire size to the outlet is too small to
carry the load required. This condition will normally show up first on the
loading system motors.

; Check the extruder screw speed pick-up proximity switch to ensure that it is

reading the extruder screw revolutions accurately.

OFE Series Weight Loss Feeders Page 35

8 OFE Feeder Options

The following is a list of options, which your OFE Series Feeder may have been
equipped with:

• RCP RS-485 remote control panel with 10 foot

(3m) cable

• Special supply hopper lid

• Supply voltage

Page 36 OFE Series Weight Loss Feeders

9 Spare Parts

9-1 Spare Parts List

OFE Series Loss-in-Weight Color Feeder

Check your individual unit for proper sizing before ordering.

Figure 2

OFE Series Customer Recommended Spare Parts List

Part no. Part description

A0553614 c Load cell, 10 KG
A0553615 c Load cell, 20 KG
A0553616 c Motor, SCR, 1/8 HP, 90 VDC
A0553617 Motor, SCR, 1/4 HP, 90 VDC
A0553618 Gearbox, 05:1, 300 RPM output
A0553619 Gearbox, 10:1, 175 RPM output
A0553620 Gearbox, 20:1, 90 RPM output
A0553621 Gearbox, 30:1, 60 RPM output
A0553622 Gearbox, 40:1, 45 RPM output
A0553623 Gearbox, 50:1, 30 RPM output
A0553624 c Gear motor, 1/8 HPSCR, 175 RPM output
A0553625 Gear motor, 1/8 HPSCR, 90 RPM output
A0553626 Gear motor, 1/8 HPSCR, 60 RPM output
A0553627 Gear motor, 1/8 HPSCR, 30 RPM output
A0553628 Display, 2 line X 1/4 inch LCD
A0553629 Switch, toggle
A0553630 c Board, CPU
A0553631 c DC voltage input board for 125 board
A0553632 c Model 125 SCR drive control board

c Indicates recommended spares. Consult factory for pricing.

OFE Series Weight Loss Feeders Page 37

10 Technical Assistance

10-1 Contact Information for Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [847] 273-7700, Fax [847] 273-7812
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specific ations, which will maximize your equipment’s performa nce
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manu al
for your convenience. ACS welcomes inquiries on all your parts needs and is dedic ated to providing
excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 233-4819 or call [847] 273-7700
Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most
products.

Sales Department

Call [847] 273-7700 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Cont act our Sales
Department for the name of the sales representative nearest you.

Contract Department

Call [847] 273-7700 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services: project planning; system
packages including drawings; equipment, labor, and construction materials; and union or non-union installations.

Page 38 OFE Series Weight Loss Feeders

10-2 Returned Material Policy

10-2-1 Credit Returns

1. Prior to the return of any material authorization must be given by AEC,
INC. A RMA number will be assigned for the equipment to be returned.

2. Reason for requesting the return must be given.

3. ALL returned material purchased from AEC, INC. returned is subject to
15% ($75.00 minimum) restocking charge.

4. ALL returns are to be shipped prepaid.

5. The invoice number and date or purchase order number and date must
be supplied.

6. No credit will be issued for material that is not within the manufacturer’s
warranty period and/or in new and unused condition, suitable for resale.

10-2-2 Warranty Returns

1. Prior to the return of any material, authorization must be given by AEC,
INC. A RMA number will be assigned for the equipment to be returned.

2. Reason for requesting the return must be given.

3. All

returns are to be shipped prepaid.

4. The invoice number and date or purchase order number and date must
be supplied.

5. After inspecting the material, a replacement or credit will be given, at
AEC’s discretion. If

the item is found to be defective in materials or
workmanship, and it was manufactured by AEC, INC., purchased
components are covered under their specific warranty terms.

OFE Series Weight Loss Feeders Page 39

10-3 Warranty

AEC, Inc. warrants all equipment manufactured by it to be free from defects in

workmanship and material when used under recommended conditions. The
Company’s obligation is limited to repair or replace FOB the factory any parts that
are returned prepaid within one year of equipment shipment to the original
purchaser, and which, in the Company’s opinion, are defective. Any replacement
part assumes the unused portion of this warranty.

This parts warranty does not cover any labor charges for replacement of parts,
adjustment repairs, or any other work. This warranty does not apply to any
equipment which, in the Company’s opinion, has been subjected to misuse,
negligence, or operation in excess of recommended limits, including freezing or
which has been repaired or altered without the Company’s express authorization. If
the serial number has been defaced or removed from the component, the warranty
on that component is void. Defective parts become the property of the warrantor
and are to be returned.

The Company is not liable for any incidental, consequential, or special damages or
expenses. The Company’s obligation for parts not furnished as components of its
manufactured equipment is limited to the warranty of the manufacturers of said
parts.

Any sales, use, excise, or other tax incident to the replacement of parts under this
warranty is the responsibility of the purchaser.

The company neither assumes nor authorizes any other persons to assume for it
any liability in connection with the sale of its equipment not expressed in this
warranty.

Page 40 OFE Series Weight Loss Feeders

-Notes-

OFE Series Weight Loss Feeders Page 41

11 Safety Tag Information

11-1 OFE Series Safety Tags

Pinch Point Read Operation
Slide Gate and Installation

Manual

Shear Point Earth Ground
Rotating Mixer

High Voltage

PE Protected Earth

Inside Enclosure Ground

Shear Hazard
Rotating Auger

Lifting Point

Page 42 OFE Series Weight Loss Feeders

11-2 OFE Series Identification (Serial Number) Tag

(Located on back of Unit)

OFE Series Loss-in-Weight Feeder

Model Number xxx-xxx

Max Blending Capacity HR

110V Serial Number 060701R
1Ǿ Date of Manufacture 06/2003

4.5A
Over-current Protection Device (s) 4.5A Total
Frequency 60Hz
Compressed air supply None

System Mass 400 lbs/(180 KG)
Electrical Diagrams &
Pneumatic Diagram

801 AEC Drive Wood Dale, Illinois USA
[phone]

OFE Series Weight Loss Feeders Page 43

Service Notes

Page 44 OFE Series Weight Loss Feeders

Service Notes

OFE Series Weight Loss Feeders Page 45

Service Notes

Page 46 OFE Series Weight Loss Feeders