Conair TrueFeed User Manual

USER GUIDE
UGB025-0806

TrueFeed™

Gravimetric Dual Feeder

www.conairgroup.com

Corporate Office: 724.584.5500 | Instant Access 24/7 (Parts and Service): 800.458.1960 | Parts and Services: 814.437.6861

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and the date you
received it in the User Guide. Our service department uses this information, along with the
manual number, to provide help for the specific equipment you installed.

Please kee p t hi s User Guide and all manuals, engi neering pri n t s a n d parts lists t o gether for
documentation of your equipment.

Date:

Manual Number: UGB025-0806

Serial Number(s):

Model Number(s):

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential
damages in connection with the furnishing, performance or use of this information. Conair makes no warranty
of any kind with regard to this information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.

Copyright 2006 l Conair l All rights reserved

INDEX

1. Introduction _____________________________________________________________________________________ 1

1.1 Symbols ______________________________________________________________________________________ 1

1.2 Terms ________________________________________________________________________________________ 1

2. General information_______________________________________________________________________________ 2

2.1 Safety ________________________________________________________________________________________ 2

2.2 Certification____________________________________________________________________________________ 2

2.3 Operating environmental conditions_________________________________________________________________ 2

3. Overview feeding unit _____________________________________________________________________________ 3

TrueFeed component overview _______________________________________________________________________ 3
Weighing frame____________________________________________________________________________________ 4
Motor and feeding system ___________________________________________________________________________ 4

4. Metering principle ________________________________________________________________________________ 5

5. Feeding systems / Capacities _______________________________________________________________________ 6

6. Installation ______________________________________________________________________________________ 8

Transport ________________________________________________________________________________________ 8
Receipt __________________________________________________________________________________________ 8
Mechanical installation ______________________________________________________________________________ 8
Changing from feeding cylinder to feed screw ____________________________________________________________9
Electrical installation________________________________________________________________________________ 10

Operation_________________________________________________________________________________________ 12

Navigation________________________________________________________________________________________ 12
Startup and Login __________________________________________________________________________________ 13
Keyboard lock_____________________________________________________________________________________ 14
Configuration _____________________________________________________________________________________ 15
Loadcell calibration_________________________________________________________________________________ 22
Material pre-calibration______________________________________________________________________________ 23
Production________________________________________________________________________________________ 25
Filling the hopper __________________________________________________________________________________ 27
Consumption______________________________________________________________________________________ 30

7.10 Alarms _______________________________________________________________________________________ 31

7.11 Files_________________________________________________________________________________________ 33

7.12 Select mode___________________________________________________________________________________ 33

7.13 Material ______________________________________________________________________________________ 34

7.14 Event log _____________________________________________________________________________________ 34

System Performance________________________________________________________________________________ 35

Reset regulation ___________________________________________________________________________________ 35

Troubleshooting____________________________________________________________________________________ 36

Appendix A: TrueFeed print view ______________________________________________________________________ 37
Appendix B: TrueFeed wiring diagram __________________________________________________________________38
Appendix C: TrueFeed technical specifications ___________________________________________________________ 39
Appendix D: TrueFeed general dimensions ______________________________________________________________40
Appendix E: TrueFeed quality checklist _________________________________________________________________ 41

1. Introduction

Thank you for purchasing a Conair Dual TrueFeed. This manual is addressed to op
technicians taking care of the feeding of dry additives to ensure correct use of the Conair feeder.

L IMPORTANT: THIS MANUAL MUST BE READ BEFORE INSTALLING THE FEEDER. KEEP THIS
MANUAL IN A PLACE THAT IS ACCESSIBLE FOR ALL OPERATORS.

It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the
User Guide. Our service department uses this information, along with the manual number, to provide help for
the specific equipment you have installed.

Please keep this user guide and all manuals, engineering prints and parts lists together for documentation of
your equipment.

Date:
Manual Number: UGB025-0806

Serial Number(s):
Model Number(s):
Software Version:

erators and qualified

Disclaimer: The Conair Group, Inc. shall not be liable for errors contained in this User Guide or for incidental, consequential damages
in connection with the furnishing, performance or use of this information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.

1.1 Symbols

L Important note

Attention safety regulations for the operator

1.2 Terms

Operator: A person ch
Qualified Technician: A specialized, suitable trained person authorized to execute the installation, non-

routine maintenance, or repairs requiring special knowledge of the machine and
how it operates.

© Copyright 2008, The Conair Group, Inc., All rights reserved

arged to operate, adjust, maintain and clean the machine.

1 Dual Feed TrueFeed Manual

2. General Information

2.1 Safety

The equipment is only designed and may only be used for the feeding of dry additives.

Any use that is not in conformity with the instructions is considered improper and as such frees the
manufacturer from any liability regarding damage to objects and/or persons.

Before switching on the unit for the first time, ensure that the main power voltage applied is between

80 VAC and 260 VAC.

Always switch off the Conair control cabinet and disconnect the main power plug from electrical power

before performing maintenance.

Ensure that all parts are securely fixed to the injection molding machine.

Dangerous voltages are still present inside the control cabinet for up to 2 minutes after the power has

been switched off.

2.2 Certification

The Conair Dual TrueFeed is designed and produced in conformity with the following European
regulations:

Standards for machinery (health, safety, environment)

EMC (electromagnetic compatibility)
VEM (safety electric material)
98/37/EC, Annex 1

2.3 Operating environmental conditions

The unit must be protected against weather conditions
Operating temperature -4 to 158 F {-20 to 70 C}.
Protection class: IP-50

2

Dual Feed TrueFeed Manual

3. Overview Feeder

3.1 TrueFeed Component overview

1 Stepper motor
2 Dispensing cylinder
3

Hopper 0.2 ft
4 Thumb knob M10x40
5 Standard NST40 Throat adaptor

6 Material discharge slide (in closed position)
7 TrueFeed Load frame

8 Slide frame (Optional)

Slide locking bolt

9

(locking the slide-out position)

Only supplied together with the optional slide mechanism

Slide locking bar

10

(locking the slide-in position)

Only supplied together with the optional slide mechanism

3

{6 liter}

L Note that the Dual TrueFeed will have two (2) of all the components listed above, except the
standard NST40 throat adapter. The Dual TrueFeed only requires one (1) throat adaptor.

3 Dual Feed TrueFeed Manual

3.2 Weighing frame

Safety bolts
(total of 4)

IMPORTANT: Do not touch the weighing frame (and dispensing unit) while feeding.
It will have influence on the feeding.

IMPORTANT: Do not touch the safety bolts under the weighing platform. These are for overload
protection. There must be some space between the safety bolts and the frame.

Transport protection pin
(Remove before operation)

Weighing frame

Hopper loader tube support
(when option selected)

Balance frame

3.3 Motor and feeding system

There are two main feeding systems, the dispensing cylinder and the feed screw.
(For more information see Section 5)

The serial number for the motor can be found on the
backside of the motor.

Motor shaft:
The motor shaft is equipped with one flat side which
fits precisely in the shaft of the dispensing cylinder.

To connect the dispensing cylinder, put it on the
motor shaft while turning it to the keyed section to find
the flat side of the shaft, then press the dispensing
cylinder completely backwards.

4 Dual Feed TrueFeed Manual

4. Metering principle

The Dispensing cylinder
ensure that the additive output is accurate and consistent. The throat adapter (mixing chamber) is designed to
blend the main material and the additive homogeneously. Conair supplies a large range of machine throat
adaptors to fit injection molding machines. The most common mounting of the throat adaptor is between the
production machine and the machine hopper. In the figure below, a cross-section of the NST40 throat adaptor
can be seen.

Standard throat adaptor

During operation, the virgin material runs from the
machine hopper through the throat adaptor into the
machine. Inside the throat adaptor the virgin material
flow is divided into two streams by the cover plate. In
the space below the cover plate, the rotating cylinder
feeds additive material.

Additive material is added directly into the center of
the virgin material flow, just before it enters the
production machine. This is a great advantage over
metering devices that use batch pre-mixing that can
cause material separation. Separation of materials
results in an irregular additive flow into the
production machine.

®

of the Conair TrueFeed is combined with a very precise adjustable stepper motor to

1

Fig. 3

1. Color 2. Virgin material 3. Throat adaptor 4. Dispensing cylinder

5. Cover plate 6. Mixing zone 7. To production machine

2

5

4 3

6

7

5 Dual Feed TrueFeed Manual

A

A

5. Feeding systems / Capacities

Depending on the application a different feeding system might be needed.
Use the following table to determine roughly the best system for the application. For more detailed information
please contact a Conair representative.

Feeding system Pellet

materials

Regrind/hard-to-

flow materials

Accuracy

Feeding capacity

Gram/sec.

GLX YES No ++ 0.01 to 1.1 0.05 to 4.1

GX YES No + 0.1 to 5.0 0.5 to 12.6

†

Feeding capacity†

Kg/hour

HX‡

A-20LT

A-20HT*
A-30HT* YES YES +/- 1.4 to 35.0

NO No ++ 0.007 to 0.4 0.03 to 1.3

YES No +/- 0.4 to 14.0 1.3 to 50.4
YES YES +/- 0.4 to 14.0 1.3 to 50.4

5.0 to 126.0

Note * Used for regrind and irregular shaped materials.

†

Note
Note

Feed rates are based on materials with a bulk density of 35 lb/ft3.

‡

For granular/free-flowing powder.

Front side view

GLX

GX

HX

20LT

20HT

A30HT

Back side view

Which type of feeding system do I need with which throat adaptor?

The last 3 numbers are related to the length of the feeding system.

TYPE CODE FOR STANDARD THROAT

ADAPTOR

CODE FOR WATER-COOLED THROAT
ADAPTOR

GLX GLX GLXC
GX GX GXC
HX HX HXC
A20LT A20 A20C
A20HT A20HT A20HTC
NOTE: The “C” suffix for the water-cooled throat adapters symbolize a longer dispensing cylinder.

6 Dual Feed TrueFeed Manual

All Conair TrueFeed feeders are equipped with a 2A (LT) stepper motor as standard. However, if you are using
an A30 feed auger, a 4.5A (HT) stepper motor will be supplied. An A20 auger can also be connected to the

4.5A (HT) motor.

Stepper motor 2A

(LT)

Stepper motor 4.5A

(HT)

L Do not select the HT setting in the control if a LT motor is connected. This will damage the motor.

If the LT motor is selected and a HT motor is connected there will be less motor torque, which can
influence the feeding.

The controller of the feeder makes a distinction between two groups of materials, normal granules and micro
granules. To determine the kind of material in your application use the description below.

Material types

Normal Granules:

(NG)

Ø

L

Ø < 4 mm L < 4 mm *

The term Micro/Mini Granules also
includes free flowing powder.

Micro / Mini Granules:

(MG)

ø

L

Ø < ø2.5 mm L < 3 mm *

* For other sizes contact a Conair representative.
The actual capacity of the feeding system depends on:

The volume weight of the material (bulk density)
The specific weight of the material (specific density)
The granular shape of the material
The granule size
The surface structure of the material

Granular material can be normal or micro. The granular material and powder material has to be free flowing,
non-static and not sticky.

7 Dual Feed TrueFeed Manual

6. Installation

6.1 Transport

To protect the Conair Dual TrueFeed gravimetric feeder against damage during transport, the unit is packaged
in a cardboard box filled with polyurethane foam. Delivery terms are FOB Franklin, PA. The buyer is
responsible for the transport. Conair cannot be held liable for any damage that might occur during transport.

6.2 Receipt

Check the unit thoroughly upon receipt. Pass any remarks to the local agent or Conair representative within
eight working days upon receipt of goods.

6.3 Mechanical Installation

Most mechanical parts are pre-assembled, making installation quick and simple.

1. When installing a main material hopper (not included with feeder purchase) on top of the throat adaptor,
the 6 x 6 inch top flange of the NST40 throat adaptor will have 5 x 5 inch pre-drilled mounting holes.

2. -Install the throat adaptor directly on top of the entrance of the production machine.

-Install the throat adaptor in a 90-degree angle to the machine barrel. This will optimize the feeding
accuracy in relation to the vibration of the production machine.

-Make sure that the complete unit is mounted
horizontally level

-Assure proper grounding to control cabinet,
throat adaptor and feeder.

3. Remove the transport
protection pin (at the bottom
of the loadcell frame) before
placing the hopper
assembly. This is just a pin
on a flexible chain, do not
dismount the stainless steel
plate!

4. Connect the hopper assembly to the throat adaptor
by turning the thumb knob clockwise. Make sure that
the thumb knob is tightened firmly.

5. Mount the controller in a vibration-free area and away
from high temperatures.

and is secure.

Transport

protection pin

Thumb knob

Main material

hopper

Hopper

Horizontally leveled

Barrel

Install the throat adapter in a 90-degree angle to the
machine barrel. As shown in the picture.

90°

(Water-leveled)

assembly

8 Dual Feed TrueFeed Manual

g

6.4 Changing from Dispensing cylinder to Feed screw

In relation to the maximum capacity of the dispensing cylinder, it might be necessary to change from the
selected dispensing cylinder to a feed screw. The feed screw system consists of a rotating auger in a

non

-rotating tube. (See the detailed instructions listed below.)

5

1

2

To install the feed auger:

1. Detach the motor quick release clamps and take out the motor from the hopper.

2. Dismount the throat adaptor connection flange (1) by removing 4 socket-head screws.

3. For use with a dispensing cylinder the throat adaptor connection flange (1) is equipped with a ball bearing

(5). When using an auger screw system, the ball bearing must be removed. The metal ring (2) that is fixed
on the feed screw tube fits directly on the throat adaptor connection flange.

4. Dismount the dispensing cylinder (3) and mount the auger screw (4) with the M5 bolt.

5. Replace the motor and auger by closing the motor quick release clamps.

For cleaning, the motor and auger can easily be removed.

POSSIBLE COMBINATIONS

3

4

A20

GX / GLX / HX

Art.nr:H000002

G / GL / H

Art.nr:H000014
Included ball bearin

L Note that the A20HT and A30HT auger
screws have a larger diameter motor

Art.nr:H000010
Included seal

mounting for the larger, high torque motor

9 Dual Feed TrueFeed Manual

shaft.

BALL BEARING
L For cleaning of the ball bearing use a dry piece of cloth or a smooth dry toothbrush to remove the dust or

moisture and foreign particles that stick.

L Following points have effect on the lifetime of the ball bearing:

o Abrasive materials
o Temperature
o Dusty/fine powder materials

6.5 Electrical installation

The Dual TrueFeed controller is equipped as standard with the following connections:

Main power cable

L Before switching on the unit for the first time, ensure the main power voltage being
applied is between 80 and 260V.

Input cable
2 Motor cables, 1 for Regrind and 1 for Color
2 Loadcell connectors, 1 for Regrind and 1 for Color
Network connection
1 controller with display (Regrind unit) and 1 controller with blind lid (Color unit)
Compressed air solenoid valve complete with cable for automatic hopper loader (Regrind)

Options are:

Alarm strobe light, complete with cable
Compressed air solenoid valve complete with cable for automatic hopper loader (Color)

10 Dual Feed TrueFeed Manual

APPENDIX B SHOWS THE PRINT VIEW WHICH WILL BE EXPLAINED BELOW

1. PROCESSOR BOARD

The processor board is the heart of the controller.
This board must be fixed securely on the main board.
There’s also a label on it with the Mac-address. This is the ID of the network card.
This address can also be seen on the startup screen.

2. EXTERNAL TERMINAL CONNECTION

This connector will be used when using an external terminal (Shielded cable max. 10 m)

3. CONNECTION TO PC OR NETWORK

An Ethernet connection will be used when using a PC or network.
Maximum length of the UTP network cable, type RJ45 (Cat. 5) is 100 meter between 2
network points.

4. INPUTS

Start input

The Dual TrueFeed needs an input signal from the production machine in order to operate.
Three different input signals can be used to control the Dual TrueFeed:

Potential free start input. (dry contact)
Potential (24 Vdc) start input
Tachometer (0-30 Vdc) start input

5. MOTOR

The Dual TrueFeed can control 2 motor types:

LT (low torque) standard motor for normal feeding
HT (high torque) motor for high output feeding

(See Section 5 for more details and wiring diagram for electrical connections, Appendix B)

6. OUTPUTS

The Dual TrueFeed has the following outputs available:

[clamp 24-25] Valve output for hopper loader, (Solid state 24VDC/0.5 A)
[clamp 22-23] Warning output (Solid state 24VDC/0.5 A)
[clamp 26-27] Potential free relay (normally open) output for Alarm (max. 230Vac/30Vdc, 5A)
[clamp 28-29] Potential free relay (normally open) output for Running contact

(max. 230Vac/30Vdc, 5A). This contact will be used to show that the motor is running.
The maximum total output power may be 12 Watt (Valve output and alarm output together max. 0.5A)
(See wiring diagram Appendix B for electrical connections)

7. POWER SUPPLY

The Dual TrueFeed will operate with a voltage from 80 VAC to 260 VAC, 50 and 60 Hz
by integrated automatic voltage selector.
(See wiring diagram Appendix B for electrical connections)

11 Dual Feed TrueFeed Manual

A

7. Operation

7.1 Navigation

Loadcell

Input LED is lighted:
Input signal is ON

Alarm LED is lighted:
Alarm / Warning

Arrow left / right:
Scroll through menus /
settings

Enter / scroll / exit MENU

Arrow up / down:
Scroll through parameters

Start input cable

Start LED blinking:
Motor is stand by / waiting for start signal
Start LED lighted:
Motor is running

Mains power switch: ON / OFF

Mains power cable

lpha-numerical

buttons:

Set values /
descriptions

Enter:
Confirm settings /
Pick up a JOB

Stop:
Stop unit

Start:

Start unit

COLOR

UNIT

REGRIND

UNIT

External communication /
Network

RJ45

Crossed

UTP cable

Valve output
for hopper loader

Output for:

-Alarm

-Warning

-Running

L Note that from the color unit the internal dipswitch 1 = ON on the main board. (see Appendix A)

Motor cable

12 Dual Feed TrueFeed Manual

7.2 Start-up & Login

Immediately after switching on the main power of the Dual TrueFeed, the software versions will be displayed.
In the first screen the software version of the terminal will be shown.

Conair Terminal
Version x.xx
Date: January 2007

After a few seconds the second screen appears for 10 seconds.

Conair TrueFeed

Color in Control

Vx.x

SP-Vx.x

MENU to continue

BL Vx.x

Mac-00:12:EC:xx:xx:xx

The Dual TrueFeed controller has three user levels:

1. Operator 2. Tooling (Supervisor – level 1) 3. Supervisor (Service – level 2)

The functions for each user level are shown in the table below.
The Operator Level is the lowest level; only the settings for production can be altered. The reminder of the

settings/menus are not displayed or are locked.
To access a different user level, enter the LOGIN menu and enter the password (4 numerals) and press

“Enter”. The passwords for the Tooling and Supervisor user levels can be defined by the supervisor in the
CONFIGURATION menu.

MENU TITLE: FUNCTION:

[LOGIN] To enter the different user levels.
[CONFIGURATION] To configure the feeding system.
[PRODUCTION] To do the production settings.

*In OPERATOR Level jobs and materials are read only.

[FILES] To look for, rename or delete jobs and curves
[HOPPER LOADER] To do the hopper loader settings,

only visible when a hopper loader is selected.

[CALIBRATION] To make material calibrations, only visible when control

mode is set to GRAVI (Gravimetric).

[LOADCELL] To calibrate the loadcell.
[WEIGHT CHECK] To check the hopper or object weight.
[CONSUMPTION] View of the total quantity of material fed by the

Dual TrueFeed.

[ALARMS] View of the alarm history

*In TOOLING level the alarm configuration is invisible.

[EVENT LOG] The history of events or settings will be logged in this

menu.

If you have forgotten your supervisor password, contact Conair Service at 1-800-458-1960.
When entering a wrong password the user level will be set automatically to Operator Level.

Vx.x = user software version Vx.x
SP-Vx.x = Language version Vx.x
(Default language is English)
SP means that the alternative language is Spanish.
BL Vx.x = bootloader software (firmware) Vx.x
Mac address = ID address of the network card

USER LEVEL

TOOLING

Default code

1111

OPERATOR

Default code

0000

Can be changed in LOGIN menu.

SUPERVISOR

Default code

2222

YES YES YES
YES NO NO

YES YES YES*
YES NO NO

YES YES YES

YES YES NO
YES NO NO

YES YES NO
YES YES NO

YES YES* NO

YES NO NO

13 Dual Feed TrueFeed Manual

7.3 Keyboard lock

The keyboard lock function:

Is accessible in the LOGIN menu.
Can only be activated and deactivated with the SUPERVISOR login code.
Is only fully functional in OPERATOR and TOOLING user levels.

For example: if the “Start user” setting is configured to “Supervisor”, the keyboard lock is deactivated as
soon as the controller is switched OFF and ON.

The following screen will appear when the LOGIN menu is entered:

USER LEVEL

Enter the password to set
the user level.
Level : SUPERVISOR
Key lock: Unlocked/Locked

MESSAGE

Keyboard locked !

To unlock enter
supervisor code.

MENU to continue

When “Locked” is selected it is still possible to:

Shift between the LOGIN, PRODUCTION and HOPPER LOADER menu.
To START and STOP the feeder.

For further information see the Start-up & Login Section 7.2.

Use the “Æ” or “Å” arrow buttons to select “Locked” or “Unlocked” for the
keyboard, then press “Enter” to confirm. When “Locked” is selected the unit will
automatically be set to OPERATOR level.

This screen will appear when a user is trying to change settings while the keyboard
is locked. To unlock the keyboard, the supervisor code must entered in the LOGIN
menu.

14 Dual Feed TrueFeed Manual

7.4 Configuration

For initial setup, the Dual TrueFeed controller needs to be setup in the CONFIGURATION menu once.
Depending on the configuration, some settings will be invisible if they are not relevant.

L Highlighted Parameters are factory settings.

Motor type : LT / HT
Cylinder type : G / GL / H / A20 / A30 / GL / GLX
Material type : NG / MG
Cal dev. : 5.0 %
Control mode : GRAVI / RPM
Input mode : Timer / Relay (Injection) (not visible in Color mode)
Input filter : (3-32) (not visible in Color mode,

only with relay selection)
Fill. System : NO / ME / MV/ GR (GR only in Regrind mode)
(MV only in Color mode)

Filling start : 800 gr. (only with ME or MV)
Hopper empty : 700 gr. (only with ME / MV / NO)
Regrind HL : 2000 gr. (only when GR selected)
Regrind lvl4 : 20% (0-80%) (only when GR selected)
Deviation alarm : 25 %
Auto start: NO / YES (not visible in Color mode)
Master reset: NONE / ALARM / MATER / ALL
IP: xxx . xxx . xxx . xxx (not visible in Color mode)
Name : xxxxxxxxxxxxxx
Start user : Operator / Tooling / Supervisor (not visible in Color mode)
Tooling passw. : xxxx 1111 (not visible in Color mode )
Supervisor passw. : xxxx 2222 (not visible in Color mode)
Date : (dd / mm / yy) (not visible in Color mode)
Time : (hh / mm / ss) (not visible in Color mode)

Configuration: Language
The standard language is English. On request also different languages are available.

Configuration: Motor type
LT is Low Torque motor and HT is High Torque motor (See Section 5 for more information)

L

Do not select HT motor if LT motor is connected.

Configuration: Cylinder type
Type of feeding cylinder / feed screw (see Section 5 for more information)

Configuration: Material type
The type of material, normal granules (NG) or micro granules (MG).
(See Section 5 for more information)

Configuration: Calibration Setpoint

The maximum allowed deviation from the Calibration Setpoint can be adjusted in this
parameter. (For more information see Section 7.6)

Configuration: Control mode
(GRAVI) Gravimetric mode (See Section 7.5) or (RPM) Volumetric mode

Configuration: Input mode
Type of input signal. (Relay, Timer)

15 Dual Feed TrueFeed Manual

timer x x
relay x
GRAVI RPM

INJ

L

Input mode is not visible in RPM Production Mode. (Timer is used automatically)

Input (start) signal

The Dual TrueFeed needs an input signal from the production machine in order to operate.
Two different input signals can be used to control the Dual TrueFeed.

1. A potential free relay contact.

Use the white and brown wire for the potential free contact.

2. A relay signal up to 30 Volt DC.

In case of a powered relay signal, connect the white wire to +24 VDC and the yellow wire to
the side. To detect a start signal, the TrueFeed needs a minimum voltage of 18 VDC.

Configuration: Input filter
The “Input filter” setting is only visible when “Relay” is selected as the Input mode.
In the Relay Input mode the length of the feeding time is measured automatically by the duration of the
incoming input signal. The Input filter calculates the average feeding time of the set number of shots (3-32)
The calculated average time is used as steady feeding time. The default Input filter setting is 3.

L

During production, if a production setting was changed or if the “Stop/Start” button was pressed, the feeding time will

reset automatically.

Configuration: Fill. System
Filling system, NO (None), ME, MV or GR (see Section 7.7)

Configuration: Filling start
Function: When it is detected that the hopper weight is 800 grams (default) or less, the filling system will
automatically start. The default value can be manually changed if necessary (depending on the material
properties).

This function is only visible when a filling system is selected.

L
Configuration: Hopper empty

The system will give a “Low Hopper Level” message if there is less then 700 grams (default) of material in the
hopper. For this system to work correctly it is necessary to calibrate the loadcell with an empty hopper and the
hopper lid in place. This system will always be active. The default value can be manually changed if necessary
(depending on the material properties).

Regrind HL
High level of the Regrind hopper. This is the weight of Regrind hopper when the hopper is filled to its maximum
capacity. (Default is 2000 grams)

Regrind lvl4

Maximum Regrind feeding percentage (Level 4 of the Regrind hopper). This value will be added to the
Regrind % setting on the Production screen. (Default is 20%)

16 Dual Feed TrueFeed Manual

Configuration: Deviation alarm

The TrueFeed automatically adjusts its motor speed to the desired setpoint. The controller is able to detect and
alarm when the setpoint is not reached within a set percentage. If, after normally performed speed
adjustments, the setpoint is consistently not reached, the controller will give an alarm signal and show
“Maximum deviation exceeded” in the display.

If the setpoint it not reached within the set percentage it is a result of:

Partial or complete blockage by sticky or hard flowing material.
Inaccurate feeding because material is not uniform in size.
Disturbance of the weight signal, for example by mechanical blocking of the TrueFeed load frame

The Maximum deviation setting can be set in the CONFIGURATION menu:

Deviation alarm: xx% (1-99%)

+ limit :

Setpoint [gram/sec.]

- limit :

Output [gram/sec]

Time

maximum deviation % setting

Example:
The Deviation alarm setting in the configuration menu is default set to 25%
The setpoint (color set) is set to : 1,000 gr/sec

-the MAXIMUM limit value will be : 1,250 gr/sec

-the MINIMUM limit value will be : 750 gr/sec

When the maximum deviation message (Error 01, page 32) appears in the display of the controller, it shows the measured deviation (in percent) of the
setpoint.

Configuration: Auto start
Enable/disable auto startup after a voltage dip or when the main power has been switched OFF.
When enabled, the unit will continue feeding automatically after a voltage dip or when the main power has
been switched OFF.

Configuration: Master reset

Reset alarm history (ALARMS). All alarm/warning messages saved in the alarm history will be

removed.

Reset material calibrations (MATER.) All material calibrations will be removed.
Reset production jobs (JOBS). All Jobs will be removed.
Reset these three together (ALL). Alarm history, material calibrations and jobs will be removed.

Configuration: IP
IP-address is used in a network environment (TCP/IP protocol). (For example 192.168.001.001)
When a Dual TrueFeed is part of a network, the controller must have an IP-address for identification.

L

This IP-address has to correspond with the IP-address of your computer. Ask your network administrator for a unique address.

17 Dual Feed TrueFeed Manual

Configuration: Name
Give a name or figures for individual identification (for use in network).
For example the name of the machine the feeder is mounted on.

Configuration: Start user (Sign-in)
Initial user level upon start-up.
(Operator, Tooling or Supervisor)

Configuration: Tooling password
Password for Tooling user level, 4 numerals default: 1111

Configuration: Supervisor password
Password for Supervisor user level 4 numerals default: 2222

Configuration: Date
Actual date: (dd / mm / yy)

Configuration: Time
Actual time: (hh / mm / ss)

LDate and Time will be stored for a minimum of 1500 hours when the Dual TrueFeed controller is OFF.

18 Dual Feed TrueFeed Manual

DUAL REGULATION

The Dual TrueFeed system functions as two gravimetric feeders with the Regrind unit as the master and the
Color unit as the slave. It is only possible to use the Dual TrueFeed system on an injection molding machine.
See the schematic below.

Virgin

Regrind Color

4
3
2
1
0

Neckpiece

Grinder

Injection molding machine

In the diagram below, the linear relation between Color feeding and the Regrind feeding is shown. The Regrind
metering unit determines the masterbatch feeding amount at the same time. To regulate the overall mix, the
Regrind metering unit needs know in advance how much regrind must be processed before the masterbatch
dose is adjusted. This is done via a master-slave control in which the Regrind metering unit is the master. The
metering unit(s) will try to achieve the optimum setpoint.

3,0%

3,0%

2,5%

2,0%

1,5%

2,7%

1,0%

% of masterbatch added to make 100% color

0,5%

0,0%

%

%

0

0

1

% of Masterbatch to add to make 100% color

in relation to % regrind to be added

(on the basis that regrind contains same color % as final product)

2,4%

2,1%

1,8%

1,5%

%

%

%

0

0

2

4

3

%

0

0

5

% of regrind

6

1,2%

%

0

7

0,9%

%

0

8

0,6%

%

0

9

0,3%

%

0

0,0%

%

0

0

1

DUAL TRUEFEED OPERATION
The Dual TrueFeed has the following two feeding modes:

Regrind mode
Color mode

19 Dual Feed TrueFeed Manual

When the Regrind mode is selected feeding can be started or stopped. Regrind configurations can also be
done in this mode under the CONFIGURATION menu.

To switch between Regrind and Color modes, go to the SELECT MODE menu and select “YES or “NO”. In the
Color mode all the Color configurations can be done. In the Regrind and Colors modes, material calibration/
selection (MATERIAL menu) and loadcell calibrations can be done.
All production settings can be done from the PRODUCTION menu in Regrind mode.

There are two ways to operate a Dual TrueFeed:

1. Without a grinder connected to the machine.

2. With a grinder connected to the machine (closed-loop)

1 Without a grinder connected to the machine.

If no grinder is connected and storage bins are used to load Regrind:

Select ME as the hopper loader in CONFIGURATION menu.
The filling of the hopper will work like a normal ME hopper loader system.
The Regrind system will feed to the Regrind% Setpoint set in the Production menu.

2 With a grinder connected to the machine (closed-loop).

Go to the CONFIGURATION menu
Select GR as hopper loader for the grinder settings
The following two additional settings will be visible:

o HL = High level of the Regrind hopper. This is the total weight of regrind material if the hopper is

filled to its maximum.
(For example, the bulk density of used of Regrind = 0.6 kg/dm3 * 6 dm3 hopper = 3600 gram or
go to the Weight Check menu, reset the weight and fill the hopper to its maximum and read the
object weight and enter this value in as HL.)

o Lvl4 = Maximum Regrind feeding percentage.
This value will be added to the Regrind % setting in Production screen.
(Default is 20%)

For example the Regrind % to be added is 20%, then the max Regrind% is 40% with the default value of Lvl4 is 20%. If this value is set to 0%, the
maximum Regrind % will be 20%

20 Dual Feed TrueFeed Manual

The Regrind hopper is divided in 5 weight levels:
Regrind% level 0: 0% Regrind

1: % Regrind medium Level 0 and Level 2
2: % Regrind set in Production screen
3: % Regrind medium Level 2 and Level 4
4: % Regrind level 2 + Lvl4 (=max. Regrind %)

Regrind hopper

Regrind

4 - Max. Regrind fill point
3 - Typical fill point
2 - Typical fill point
1 - Typical fill point
0 - Refill Trigger point

For example: Regrind% set in Production screen is set for 20%
Lvl4 is set to 20%
Regrind% level 0: 0% Regrind
1: 10% Regrind
2: 20% Regrind
3: 30% Regrind
4: 40% Regrind

The values of Level 1 and 3 will be automatically calculated.
Based upon the amount of regrind present in the regrind hopper, the feeding level of the Color unit is
automatically adjusted.

When the Regrind hopper is empty (below Level 1) only the Color will be fed at the set Color%.
The hopper loader will fill with intervals fill offtime 2 (fast filling).
The Regrind unit starts feeding if the Level is between Level 2 and 3.
The hopper loader will fill now with intervals fill offtime 1 (normal operation)
If the Regrind weight rises above Level 4, filling of the hopper will stop until the weight is again between
Level 2 and 3.

7.5 Loadcell calibration

Two types of calibrations are available with the Dual TrueFeed, depending on the selection made in the
Configuration menu :

1. Automatic - The advantage of automatic over manual calibration is that the automatic calibration is
self-calibrating and the probability of failures will be reduced. Also, the accuracy is higher with changes
of output because a complete curve of the material will be made.

2. Manual - Running in RPM mode (external scale needed)

21 Dual Feed TrueFeed Manual

When using a TrueFeed for the first time, do an initial loadcell calibration as follows:

The unit must be mounted horizontally (water-leveled)
Avoid vibrations during the loadcell calibration. This will influence the calibration.
Do not touch the unit during loadcell calibration.
When using the optional slide frame, the whole unit must be slid completely in against the throat adaptor

and fixed.

Be sure that the TrueFeed loadcell is connected to the controller
Go to the LOADCELL menu
In this menu it is possible to calibrate the loadcell of the TrueFeed

(500gr. Calibration weight required)

Select “YES” to start the loadcell calibration

LOADCELL CALIBRATION

[***]

Status

Calibration busy.
Please wait…………..

After a few minutes the following screen appears:

LOADCELL CALIBRATION

[***]

Status

Place weight, press
START when ready.

After approximately 1 minute the loadcell calibration is ready, press the “MENU” button to continue.
To check if the loadcell calibration was OK, go to the WEIGHT CHECK menu.

WEIGHT CHECK

Weight: gr. ><
Object: gr.

Zero: NO/YES

‘Zero’ the object weight
Place 500 gr. calibration weight on the hopper
If the object weight is not corresponding with the real weight, perform another loadcell calibration.

[***] = Progress

Place calibration weight (500 gr.) on the hopper
and press the “START” button

><: Standstill sign. When the vibrations are too big, this sign disappears!
Weight: Actual weight on the weighing scale (gram)
Object: Object weight (gram)
Zero: Zero YES / NO. Reset the object weight.

22 Dual Feed TrueFeed Manual

7.6 Material Pre-calibration

The TrueFeed can be started in two ways:

1. Start the unit without
After pressing the “START” button the unit starts feeding on a speed that is based on default curves
which are pre-programmed in the controller. After start-up, the unit continues with self-calibrating to the
setpoint.

2. Start the unit with
After pressing the “START” button the unit starts feeding on a speed that is based on material
calibrations made by the user, which are stored in the controller. After start-up, the unit continues with
fine-tuning to the setpoint.

What is the function of material Pre-calibration?
With pre-calibration it is possible to calibrate the unit before production is started; this way the time needed to
be in specification can be reduced. The TrueFeed is a gravimetric/loss-in weight feeder. When starting up the
feeder for a new production run, there is no direct information available about the loss in weight. Of course you
want the feeder to reach its setpoint with the matching speed of the motor (RPM) as quickly as possible.
Starting the unit with a speed that is already near to the setpoint will achieve quicker regulation. The correct
RPM at the start of the feeder can be determined automatically with a pre-calibration.

The pre-calibration can be done in two ways:

pre-calibrating the material.

pre-calibrating the material (OFF-LINE).

1) Unit with option slide frame: 2) Unit without optional slide mechanism:
Slide the frame with unit backwards till the “click”. Remove the feeder and put it on the frame like shown.

It is important that during calibration the feeder is mounted fixed and horizontal and also vibration free.
Before starting a material calibration ensure that the hopper is filled with sufficient material.
Be sure that the loadcell cable is connected to the TrueFeed controller.

The following parameters will be stored with a Material calibration, depending on the configuration:

CONFIGURATION parameters: Cylinder type : type of feeding cylinder or feed screw

Material Type : Normal or micro-granules

PRODUCTION parameters: Shotwth. : Shot weight

Color% : Color amount (%)
Dos.time : Feeding time (sec)

CALIBRATION parameters: Material name : Name of calibrated material

23 Dual Feed TrueFeed Manual

How to make a material calibration

Go to the CALIBRATION menu.
Enter the Material name and your production parameters.
Start calibrating. The following screen appears:

Set : 1,000 gr/s

Actual : 0.945 gr/s

Stop & Store : YES/NO

CALIBRATION

[TESTING BUSY]

[*****]

Material calibration will take approximately 3 minutes but can take more time depending on the material

used and production parameters.
It is possible to stop

during the calibration (for example to refill the hopper).

To continue select “YES” and press “ENTER”. To stop select “NO” and press “ENTER”.

The calibration will automatically be finished and saved after the setpoint is reached within the set

calibration deviation (Cal dev: default = 5%) set in the CONFIGURATIONS menu. (see Section 7.4)

After saving, the control will automatically go to the PRODUCTION menu and the stored calibration will

automatically be selected.

L

Stored material curves have a * after the filename.

During the calibration the unit is regulating to its setpoint. When this point is reached the calibration will
automatically be saved. On the basis of this point, a complete curve is made using the default
pre-programmed curves.

Material Calibration

Single point calibration on basis of
pre-programmed curve

How can I select a calibrated material?

When one or more material calibrations are made, one can be selected as follows:

Go to PRODUCTION menu
Use the cursor to go to Material.
Press and hold the “ENTER” button for two (2) seconds. A list will appear with stored material

calibrations

Select the desired material calibration with the selection arrow buttons and press “ENTER”.

If the material calibration made is not in the list, fill in the first letter(s) and press “ENTER”. A filtered list will
now appear. To go back to the main list, fill in with blank spaces and press “ENTER”.
It is also possible to fill in the material description immediately in the PRODUCTION menu and press “ENTER”.
The message “Material not found, select new material” appears when a false material is filled in. To clear
the material description, fill in with blank spaces or select an empty material calibration from the list and press
“ENTER”.

How can I delete or rename a calibrated material?

To delete one or more material see Section 7.13.
To delete all Materials, select “Master Reset Material” in the CONFIGURATIONS menu and press “ENTER”.

24 Dual Feed TrueFeed Manual

7.7 Production

L

The rotation direction of the feeding from the front view must be to the right (clockwise)

LSee Section 7.4 for the operation and regulation of the DUAL TRUEFEED.
Production (Motor On/Off)

Press the

“START” button to begin feeding. (Only possible in Regrind mode)
The start LED blinks when the unit is waiting for an input signal.
The unit is feeding if the Start LED lights continuously.
When the unit is started the actual production data will be shown.
Press the

“STOP” button to stop production.

L Please notice that it is possible that the first feeding(s) are not sufficient, because the cylinder is filling with material.
The feeding cylinder require time to stabilize.

The unit will switch automatically to the STATUS screen.

PRODUCTION SETTINGS

Color % : %
Regrind %: %
Shot wth.: gr
Dos.time : s
Test : NO/YES

INJECTION MOLDING
The following parameters can be seen in the production screen, depending on operation or settings (made in

Supervisor mode):

Injection molding/Gravimetric mode

Production Settings

PRODUCTION SETTINGS

Color % : %
Regrind %: %
Shot wth.: gr
Dos.time : s

Test : NO/YES

Actual production data L

If there’s not yet a value known *** will be displayed

PRODUCTION DATA

REGRIND COLOR
Set: x.xxx x.xxx gr/s
Act: x.xxx ***** gr/s
Wth: xxx>< xxx>< gr
Tim: x.x sec
RPM: x.x x.x rpm

Sts: Std.by Std.by

3 levels of production screens:

COLOR REGRIND

x.xxx% x.xxx%

CAL/OK CAL/OK

STATUS

The status switches from “CAL” =
CALIBRATING to “OK” when the
deviation between set output and
actual output is less than 10%

(Menu Button)

PRODUCTION DATA

REGRIND COLOR
Set: x.xxx x.xxx gr/s
Act: x.xxx ***** gr/s
Wth: xxx>< xxx>< gr
Tim: x.x sec
RPM: x.x x.x rpm

Sts: Std.by Std.by

Color % : Color amount (%)
Regrind%: Regrind amount (%) (0-80%)
Shot wth : Shot weight (gr.)

Dos. time : Feeding time (sec.) LFeeding time only visible in Timer mode
Test : Initial production test with set speed and time

Actual color output is only visible after the first automatic RPM adjustment.

Set. : Calculated output (gr/sec)
Act. : Actual color output (gr/sec)
Wth. : Material weight in the hopper

>< : Standstill sign. When the vibrations are too big, this sign disappears!
Tim : count down of the actual feeding time (sec)
RPM : Actual motor speed (RPM)
Sts : Status of the feeding, Standby/feeding/filling

25 Dual Feed TrueFeed Manual

Injection molding / RPM mode
Production Settings

PRODUCTION SETTINGS

Set speed: rpm
Dos.time : s
Test : NO/YES

Set speed: Set motor speed (RPM)
Dos.time : Actual feeding time (sec), measured from relay
Test : Initial production test with set speed and time

Actual production data

PRODUCTION DATA

Speed : rpm
Time : sec

Status :

Speed : Actual motor speed (RPM)
Time : Count down of the actual feeding time (sec)
Status : Status of the feeding, standby/feeding/filling

How can I select a calibrated material?

When one or more material calibrations are made, one of these can be selected as follows:

Go to MATERIAL menu
Press and hold the “ENTER” button for two seconds.

A list (max. 10) will appear with stored material calibrations

L

(The materials with a * after their names are multi-point calibrations)

Select the desired material calibration with the selection arrow buttons and press “ENTER”.

If the material calibration is not in the list (because of max. 10 in the screen) fill in the first letter(s) of the
calibration name and press “ENTER”. A filtered list will now appear.
To go back to the main list fill in with blank spaces and press “ENTER”.

To clear the material description, fill in the spaces or select an empty material calibration out of the list and
press “ENTER”.

How can I delete a calibrated material?

For deleting one or more material calibrations see Section 7.10
To delete all Materials, select “Master Reset Material” in the CONFIGURATIONS menu and press

“ENTER”.

Test function

With the Test Function both units will feed material with the set feeding time and set/calculated speed.
Do a test as follows:

Go to PRODUCTION menu
Fill in the production settings
Use the arrow buttons to go to “Test”
Select “YES” and press “ENTER”
The unit will run with the set parameters.

To stop the test, press the “STOP” button.

26 Dual Feed TrueFeed Manual

7.8 Filling the hopper

MANUAL FILLING

The controller automatically detects when the hopper is manually filled. During the time that the hopper is
being filled, the TrueFeed is feeding with a fixed RPM, this means the unit runs temporarily volumetric. As soon
as the hopper filling is complete, the TrueFeed immediately resumes working gravimetric.

AUTOMATIC FILLING (optional)
Introduction

Conair Truefeed feeders are capable of handling a variety of pelletized materials. Two different filling systems
are available depending on the material properties.

The Conair Ejector (ME) system is for dust-free or nearly dust-free materials.
The Conair Vacuum (MV) system is for materials that are NOT entirely dust free.

The ME and MV systems are both driven by low-pressure compressed air and mounted directly on top of the
hopper lid of the TrueFeed. The TrueFeed controls the operation of the ME or MV systems.

All parts are aluminum or stainless steel and are virtually maintenance-free. Only the filter needs to be cleaned
periodically. To increase reliability and safety, there are no moving parts except for the pneumatically-operated
closing valve of the MV system.

How the ME works

The ME system blows the material from a bag, drum or container into
the feeder’s hopper. The hopper lid of the housing has a simple and
easy-to-clean dust filter to keep any dust particles in the hopper.
The system is triggered by the filling start weight (CONFIGURATION menu).
This parameter also generates a low-level alarm if the hopper is empty.

How the MV works

The MV system uses a 3-stage vacuum generator driven by compressed air
to create a vacuum that draws material into a chamber that closes. Once the
chamber is filled with material, the cone that closes the chamber will open
and the material will be discharged into the hopper.
The system is equipped with a superior filter to ensure that the finest
particles (> 5 micron) stay in the system and are not released into the
atmosphere. This makes the MV system the most practical and user-friendly
system for both free-flowing powders and granules.

General

LThe hopper loader is only activated when the motor is On

.
L Emergency stop.
To stop the hopper loader during production go to the HOPPER LOADER
menu and switch the ME or MV system to OFF.

ME hopper loader

MV hopper loader

27 Dual Feed TrueFeed Manual

Hopper loader settings

This part of the manual describes how to configure the hopper loader. For further technical information about
the hopper loader consult the specific hopper loader manual or contact a Conair representative.

There are three ways to fill the hoppers:

1. Manual

2. Automatic with ME hopper loader

3. Automatic with MV hopper loader

Manual

Open the hopper lid and fill the hopper by hand. (Filling will be detected automatically)
The message “Low hopper level” appears when the hopper is empty.
(Default 700 gr. In CONFIGURATIONS menu)

ME hopper loader (TrueFeed hopper loader operated by compressed air)

ME FILLING SYSTEM

ME system : OFF/ON
Fill time : 30 sec
Alarm time : 31 sec
Alarm mode : OFF/ON
Manual fill: NO/YES

L Highlighted Parameters are factory settings.

ME system: Switch on ME hopper loader system using the “ON/OFF” toggle button.
Fill time: Fill time [sec.], during this time the system blows material into the hoppers of the

Alarm time: Fill Alarm [sec.], if the hopper weight is not above the 800gr. within this time, the
Alarm mode: ME hopper loader is ON / OFF during fill alarm.

ON = ME Hopper loader stays activated during a filling alarm.
OFF = ME Hopper loader will be deactivated during a filling alarm.

Manual fill:

feeding units.
alarm will activate. The alarm time must be higher than the fill time.

Yes = starting filling immediately; No = stop filling immediately

Only visible with controller in STOP mode.
For example, the Manual filling function can be used to fill the hopper before the
start of production.

With GR (Granulator Regrind) function

When the injection molding machine is connected to a grinder, GR must be selected in
CONFIGURATIONS menu. The HOPPER LOADER menu will show the following settings:

FILLING SYSTEM

Fill system : OFF/ON
Fill time : 20 sec
Fill offtime1 : 300 sec
Fill offtime2 : 60 sec
Manual fill : NO/YES

Fill System: Switch on ME hopper loader system using the “ON/OFF” toggle button.
Fill time: Fill time [sec.], during this time the system blows material into the hoppers of
the feeding units.
Fill offtime1: Time interval between fillings during normal operation.
Fill offtime2: Time interval between fillings during startup (with empty hopper)

Manual fill:

Only visible with controller in STOP mode.

Yes = starting filling immediately; No = stop filling immediately

For example, the Manual filling function can be used to fill the hopper before the
start of production.

MV hopper loader (TrueFeed hopper loader operated by vacuum)

MV FILLING SYSTEM

MV system : OFF/ON
Fill time : 20 sec
Empty time : 05 sec
Fill cycles : 3 x
Alarm cycles: 10 x
Alarm mode : OFF/ON
Manual fill: NO/YES

L Highlighted Parameters are factory settings.

MV system: Switch on MV hopper loader system using the “ON/OFF” toggle button.
Fill time: Fill time [sec.], during this time the MV system sucks material into the vacuum

Empty time: Empty time [sec.], during this time the cone that closes the chamber will open
Fill cycles: Number of extra fill cycles after the hopper weight is above the 800gr.

Alarm cycles: Number of idle fill cycles before fill alarm. The number of alarm cycles needs to
Alarm mode: MV hopper loader is ON / OFF during fill alarm.
OFF = ME Hopper loader will be deactivated during a filling alarm.

Manual fill:
Only visible with controller in STOP mode.

chamber.
and material falls down into the hopper of the feeding unit.

be more than the number of Fill. cycles.
ON = ME Hopper loader stays activated during a filling alarm.

Yes = starting filling immediately; No = stop filling immediately

For example, the Manual filling function can be used to fill the hopper before the
start of production.

28 Dual Feed TrueFeed Manual

Output signals

During fill time there will be a 24VDC signal between connections 24 and 25 on the main board to activate the
pneumatic solenoid valve.

When the Fill Alarm is activated the controller itself activates an audible beeping signal and the alarm strobe
flashes.

GENERAL RECOMMENDATIONS FOR OPTIMAL HOPPER FILLING

To guarantee the optimal working capacity of the gravimetric TrueFeed feeding unit it is important to use the
correct rate of hopper filling. The higher the output of the feeding unit (kg/h), the more important the rate of
hopper filling.

During hopper filling, the electronics of the TrueFeed controller recognizes automatically that the hopper is
being filled. This automatic filling detection will work for the manual filling of the hopper and

the filling with an

automatic hopper loader.
During the time that the hopper is being filled, the TrueFeed is feeding with a fixed RPM, this means that the

unit runs temporarily volumetric. As soon as the hopper filled, the TrueFeed immediately resumes to work
gravimetric.

Because the TrueFeed is working volumetric during a hopper filling it is recommended to reduce the amount of
filling cycles, by increasing the time between filling cycles. This can be performed when using the correct
settings of the “Filling start level” and the “Filling stop level”.

Sight glasses

The moment when the automatic filling starts depends on
the entered start level:

Filling start: xxx gr. (Configuration menu)

Filling start level

Filling stop level is dependant on the entered fill time
for the ME-system:

Fill time: xxx sec

For the MV-system:

Fill time: xxx sec
Empty time: xx sec
Fill cycle: …. x

(Hopper loader menu)

Filling stop level

29 Dual Feed TrueFeed Manual

Recommended settings for ME hopper loader:

For the filling start weight, use a level shown in the filling start figure on the previous page. When using

a high weight level the amount of filling cycles will increase.

Use a fill time that will allow the material to cover at least the sight glass in the back of the hopper.
Overfilling of the hopper should be avoided.

Recommended settings for MV hopper loader

For the filling start weight, use a level shown in the filling start figure on the previous page. When using

a high weight level the amount of fill cycles will increase.

Use a fill time that will allow the vacuum chamber of the MV-Loader to be almost completely filled.
Overfilling of the vacuum chamber should be avoided.
Do not use an empty time that is longer than necessary, but not too short of an empty time that can

cause a decreased capacity of the MV-hopper loader.

For the amount of filling cycles, use a cycle amount that will allow the material to cover at least the sight

glass in the back of the hopper. Overfilling of the hopper should be avoided.

7.9 Consumption

The CONSUMPTION menu will be visible when the ME or MV filling system is enabled in the
CONFIGURATION menu. Without use of the optional ME or MV filling system, accurate working of the
consumption registration is not supported.

With the Consumption function it is possible view the total quantity of material feed by the TrueFeed. The
consumption is saved in the memory and remains in the memory even when the unit is shut off or unplugged.
To reset the consumption go to Reset and select “YES” and press “ENTER”.

30 Dual Feed TrueFeed Manual

7.10 Alarms

GENERAL

To reset an alarm/warning press the “STOP” or “MENU” buttons.
When an error occurs using the TrueFeed, the display will indicate an error code and description.
Together with the displayed error an output contact will be switched.
The controller itself gives a beeping signal and the alarm LED will illuminate.

To distinguish a Warning or Alarm:
Warning: Warning output is ON, but the feeding unit continues running

(24VDC contact, pin 22-23 of the main board will be active,
for example to activate the alarm strobe)

Alarm: Alarm output is ON and the feeding unit stops running
(Potential free contact, pins 26-27 of the main board will be active, for example to

stop the injection molding machine)
Free programmable errors can be configured to an Alarm or Warning.

For setting the free programmable outputs to an alarm or warning, enter the ALARMS menu.
First the alarm history will be shown. The alarms and warnings will be stored here.
When you press the “MENU” button again you will enter the alarm configuration menu.
Here you can set the alarm or warning output with

ALARM HISTORY

All alarms and warnings will be stored in the alarm history.

Go to the ALARMS <menu>
Press

to scroll to the stored alarms (max. 50).

The alarm history can be reset by the supervisor in CONFIGURATION <menu> by

Master reset: Alarm

Listed below are the following Errors

Error
Code Warnings

00 Low hopper level Material is below the hopper empty weight
01 Maximum deviation exceeded The deviation of the material output is too high
02 Filling system unable to load material Fill system is not working correctly
03 Maximum RPM exceeded, change

dispensing cylinder for higher capacity
05 Calibration, no weight change No weight change while calibrating
07 Minimum motor speed < 0.1 RPM Calculated motor speed is too low

Alarms

08 Motor connection failure Motor not connected/Motor or connection damaged
09 Parameters damaged Check configuration parameters
10 Parameters set to factory defaults Check all parameter settings
11 Loadcell calibration set to factory defaults Recalibrate the loadcell
13 Loadcell connection failure Loadcell connection is not correct
14 UDP link error No Ethernet connection between the Regrind and Color units
15 Software version mismatch Software versions of the Regrind and Color units are different

:

31 Dual Feed TrueFeed Manual

and press “ENTER”.

Calculated motor speed is too high

WARNINGS

All warnings are self-eliminating, except Error code 05.
It is possible to cancel a warning, but when the error remains, the warning will return after 60 seconds. This
gives the operator time to solve the problem without having the alarm on.

Error 00 “Low hopper level” [free programmable]

If this warning appears, the material in the hopper is below the hopper empty weight
(700 gr.)
In CONFIGURATION menu this setting can be changed.

- Check to see if there’s enough material in the hopper.

- Check the hopper empty setting in CONFIGURATION menu

- Check to see if the hopper loader is working properly.

Error 01 “Maximum deviation exceeded” [free programmable]

If this warning appears, the feeding output (grams/sec) is consistently not within set
percentage. See page ? for more information.

Error 02 “Filling system unable to load material”

If this warning appears, the alarm time (ME hopper loader) or alarm cycles (MV hopper
loader) are exceeded.

- Check to ensure there is enough material in the hopper.

- Check if the material is clogged.

- Check the operation of the hopper loader.

- Check the hopper loader settings.

Error 03 “Maximum RPM exceeded, change feeding tool for higher capacity”

Calculated motor speed is higher than the maximum of 200 RPM

- Check the material output on 200 RPM.

- Check the production settings.

- Increase the feeding time (if possible)

- Take another dispensing cylinder with higher output, for example a feed screw A20

Error 05 “Calibration, no weight change”

No weight change while calibrating (see Section 7.6)

- Check to ensure there is enough material in the hopper.

- Check if material is stuck in the feeding cylinder.

- Check to ensure the loadcell is connected correctly.

- Check the weight data by doing a weight check (See Section 7.5)

- Check to see if there are vibrations that may have influence.

- Check the rotation direction of the dispensing cylinder. Front view to the right

Error 07 “Minimum motor speed < 0.1 RPM”

Calculated motor speed is lower than the minimum of 0.5 RPM

- Check to see if there’s enough material in the hopper.

- Check the production settings.

- Decrease the feeding time (if possible)

- Use a different dispensing cylinder type with lower output, for example a GL-cylinder

- Check the rotation direction of the dispensing cylinder. Front view to the right

32 Dual Feed TrueFeed Manual

ALARMS
Error 08 “Motor connection failure”

Motor connection is not correct.

- Make sure the motor is connected.

- Check cable and connectors for damage.

Error 09 “Parameters damaged”

Some configuration parameters are incorrect.

- Check the configuration parameters.

Error 10 “Parameters set to factory defaults”

All parameter settings are reset to factory defaults.

- Check all parameter settings.

Error 11 “Loadcell calibration set to factory defaults”

Loadcell calibration is incorrect and is reset to factory defaults.

- Recalibrate the loadcell.

Error 13 “Loadcell connection failure”

-Loadcell connection is not correct.

-Loadcell connector is not connected to the controller.

Error 14 “UDP link error”

No Ethernet connection between the Regrind and Color units

- Check network connections

- Check If IP-address is configured in CONFIGURATION screen

Error 15 “Software version mismatch”

Software versions of the Regrind and Color units are different.

- Check software versions of both units.

7.11 Files

In this “File manager” menu, files (Material curves) can be searched, renamed and deleted.
When entering the file manager menu, it will allow you to search and select from the material (material
calibration) files.

To search the material files:

1. After confirming, the file list will be shown. Now you can search for files, rename or delete them.
If the Material curve you are searching for is not in the list fill in the first letter(s) or complete name and press
“ENTER”. Now a filtered list appears. (To select a program press “ENTER” and then press Confirm)

2. To go back to the main list fill in with spaces and press “ENTER”.
It is also possible to fill in the Material description immediately in the File Manager and press “ENTER”. To
clear the description, fill in with spaces or select an empty file out of the list.

Search:
Delete:
Rename:

= Scroll through the files.
= Delete a file, press “ENTER” to confirm.
= Rename a file, press “ENTER” to confirm.

7.12 Select mode

In this menu, you can switch from Regrind to Color modes to:

Do configuration settings
Make loadcell calibrations
Make/Choose material calibrations

Set hopper loader (if selected)

33 Dual Feed TrueFeed Manual

7.13 Material

In this menu, the Material curve can be selected. (See Section 7.6)

7.14 Event Log

Setting changes made with the controller are stored in the Event Log.
Each event is filed with a record number, date and time.

Approximately 7,000 events can be stored in the memory of the controller, if the memory gets full the last event
will be logged and the oldest event will be deleted (first in/first out shift register).
It is possible to store these events to a PC.

Show latest events

(Steps of 1 event)

Show previous events

(steps of 10 events)

Rec nr: 0093/0093

01/01/06 20:53

Log: ALARM NR.

Old: 8.0

New: 0.0

Show previous event

Event Log of Alarms
The error code of an alarm or warning will be logged when an alarm or warning occurs.

The error codes can be found in Section 7.12

Rec nr: 0078/0078

01/01/06 20:53

Log: COLOR PCT

Old: 2.0%

New: 1.8%

To effectively use the Event Log, be aware that the correct data and time must be set in the CONFIGURATION
menu.

34 Dual Feed TrueFeed Manual

EVENT LOG

(Steps of 1 event)

EVENT LOG

Show latest events

(steps of 10 events)

Record. number: 0000 of 0000
The first number shows the record

number of the event that is displayed.
The second number shows the total

amount of records/events that are
logged.

8. System performance

System performance can be characterized by the time it takes the unit to reach the desired setpoint, the
accuracy of the setpoint and the regularity of the material output.

The algorithm is self-adjusting to the conditions and because the conditions vary, it cannot be predicted how
long it will take the unit to adjust itself and reach a setpoint with certain accuracy.

The following variables influence system performance:

Material properties. Easy flowing, non-sticky and non-static material that comes in the form of small

granules or powder can be dosed very accurately and consistently. The accuracy and consistency of
material output drops with increased granule size. However this is only a problem with extremely low
outputs.

Periodical cleaning of the feeding cylinder and seals is necessary for proper operation.
Extreme vibrations and shocks influence system performance noticeably. Normally the system will be

able to compensate for vibrations and shocks.

The Dual TrueFeed algorithm needs a certain time to weigh material loss and adjust the RPM accordingly. This
time depends largely on the setpoint and the above mentioned three variables. The system constantly adjusts
itself to reach the best possible accuracy for current conditions. Over time it can reach an accuracy within
1%. Under “normal” circumstances the unit will be more accurate than 10% after the first adjustment of the
RPM.

Before the unit makes its first RPM adjustment it might be running already very close to the desired setpoint
because it uses a cylinder and material reference system to determine the first RPM setting. This accuracy,
however, cannot be guaranteed because material properties can vary substantially from material to material.

With injection molding, the shot to shot accuracy depends, besides the variables mentioned so far, on the shot
time. If big and heavy granules have to be dosed in a very short time this will influence the shot accuracy and
repeatability because one granule can make a difference of a few percent to the shot weight.

An unstable relay signal has a negative effect on the accuracy, repeatability and speed of the system because
it will adjust to these parameter changes.

A long cycle time combined with low dosage per shot can result in a slow system.

8.1 Reset regulation

Changing one parameter during production will cause the balance to adjust to the changes but it will not

reset the regulation totally.

Changing more production parameters during production within 10 seconds after each other will cause

the TrueFeed’s regulation to reset. This is necessary for the system to adjust quickly to these big
changes in the settings.

Switching the power OFF and ON again will also cause the regulation to reset.
Motor OFF and ON again will only cause the regulation to pause. The start-up RPM will be the same as

the last RPM before the stop.

Changing one parameter with motor OFF causes total reset of the regulation.
With auto start = ON (CONFIGURATION menu) the motor follows the last status (motor Standby or

motor Stop status) and causes total reset of the regulation.

35 Dual Feed TrueFeed Manual

9. Troubleshooting

Problem: The Dual TrueFeed does not come into specification or a Maximum deviation alarm occurred.

Possible causes:

1. Check to ensure all cables are connected correctly.

2. Check to ensure the transport protection pins are removed from the loadcell safety bolts.

3. Check to ensure the hopper assemblies are fixed tightly to the weighing platforms and that the neckpiece is fixed
tightly to the production machine.

4. Check to ensure the feeding cylinders are tightly fixed to the motor shafts.

5. Excessive build-up of material on the feeding cylinders may have an impact on proper feeding.

To avoid this, be sure that the seals and feeding cylinders are clean.

6. Check to ensure there is no tension on the cables connected to the weighing platforms.

7. Use the weight check function with the reference weight to determine the correct function of the weighing system.

8. If the weight check gives the correct result, check if the material flow into the cylinders has been blocked.

9. Another cause may be an obstruction to the weighing system. Check if there is at least 1mm space between all
the pointed screws and the loadcell frames or platforms and that there is no material or dirt blocking the
movement.

10. In case of a water-cooled neckpiece, check if there is material build-up around the feeding cylinders and the
water- cooled pipe that can obstruct the free movement of the weighing system.

11. Check if the input signal is stable.

12. If none of the above causes the problem, recalibrate the system and try the weight check again.

Problem: The Dual TrueFeed does come into specification but it seems to be slo w.
Possible causes:

1. Extreme vibrations and shocks to the system.

2. Extremely low setpoint. See Section 8: SYSTEM PERFORMANCE

3. In case of use of an automatic hopper loader, check to ensure the hoses are connected correctly.

Problem: The input/start-signal is connected but the unit does not recognize the start signal.
Possible causes:

1. Check if the correct wires are connected for potential free contact, potential contact or tacho. Also check if the (+)
and (–) sides are connected correctly.

[See Sections 6.5, 7.4 and the Wiring diagram in Appendix B.]

2. The first delivered series controllers had a different main board than the present ones. The changes in the wiring
diagram for main boards with the code MVC000BA02 (version 2) regarding to the MVC000BA03 (version 3) can
be seen in Appendix C.

The version code is printed on the main board.

3. Automatic fuse is activated; for example this can happen when there was a short circuit at the input connection.
To deactivate the automatic fuse, the controller needs to be switched OFF for a period of time and ON again, but
first check and repair the short-circuit.

Problem: The hopper weight is not stable.
Possible causes:

1. Check if the weighing signals are not influenced by external circumstances, for example if the loadcell cable
passes near electromagnetic fields or electro motors.

2. Extreme vibrations and shocks to the system.

3. Check to ensure there is no obstruction to the weighing frames.

4. In case of use of an automatic hopper loader, check to ensure the hoses are connected correctly.

36 Dual Feed TrueFeed Manual

APPENDIX A: TrueFeed Print view

INSIDE VIEW OF THE CABINET

37 Dual Feed TrueFeed Manual

APPENDIX B: TrueFeed Wiring diagram

Only with Dual TrueFeed

38 Dual Feed TrueFeed Manual

APPENDIX C: TrueFeed Technical Specifications

Controls:

Set and actual % setting for injection molding and extrusion
Extrusion control by relay or tachometer
Injection molding control
Automatic metering time synchronization or by manual timer
Manual speed and time setting
Speed: Manual setting from 0,1 to 200 RPM max, in increments of 0,1 RPM.
Time: Manual settings from 0,1 to 99,9 sec in increments of 0,1 sec.
3 keyboard lock levels
Integrated hopper loader controller

Monitoring/System Information/External communication

128 x 84 full graphic LCD front display with integrated backlight.
Man/Machine interface: Using full language command structure
External Communication: PC link using TCP/IP internet protocol; optional RS232 or 485 available
Alarm: 2 user alarm levels

Specifications/Standards & Directives/ Technical data:

Power supply: Operating power from 80 VAC to 260 VAC, 50 and 60 Hz
Power consumption: 80 Watt maximum

Stepper motor: (1,8degr/step) max 2A or 4A(high output) at 40 Volt.
Operating temperature: -20 to +70 degr. C.
Loadcell and electronics: 20 bits A/D resolution with a full digital filtering

Input signal(s):

Injection molding: Start/Stop trigger input, potential free or 24VDC*
Extrusion: Start/Stop trigger input, potential free or 24VD C*

* Note potential contact
Guaranteed OFF: 0-8VDC
Guaranteed ON: 18-30VDC

Output(s):

-Stepper motor max. output 2A or 4A(high output) at 40 VDC

-Solid state 24VDC/0.5 An output for valve hopper loader

-Solid state 24VDC/0.5 An output for external warning

-Relay for alarm level (max. 230Vac/30Vdc, 5A)

-Relay for running contact (max. 230Vac/30Vdc, 5A)

-Maximum total output power: 12 Watt (Valve output + alarm output)

Standard Directives:

Protection class: IP-50
According to CE standards:
EN50081-2 (HF radiation industry)
EN50082-2 (HF immunity industry)

Safety

In case of overload due to short-circuit or incor rect connection, the power supply automatically shuts down.
Opto-insulated start input for connection to production machine.

Machine connection flange:

Standard flange NSt40-neckpiece with cleaning opening.
Inlet/outlet ø76.2mm, steel epoxy coated RAL 3002

Loadframe:

- Balance frame: Steel, epoxy coated RAL 3002

- Weighing frame: Aluminum, epoxy coated RAL 9005

- Loadcell : Nominal Load: 20 kg.
Temp. compensated
Temp. range: -20 to +60 gr. Celcius
Protection level: IP63 EN60529

Optional parts

12 liter hopper stainless steel.
Flange type NSt90 with cleaning opening and inlet/outlet Ø50mm/ 90mm, steel epoxy coated.
Water-cooled flange BH(A) inlet/outlet 50mm/50mm stainless steel ANSI 304.
Water-cooled flange PHA inlet/outlet 100mm/100mm
Hopper loader type ME
Hopper loader type MV
Mixers
External Alarm Flash light.

External Alarm Siren.

by integrated automatic voltage selector

39 Dual Feed TrueFeed Manual

APPENDIX D: TrueFeed General Dimensions

40 Dual Feed TrueFeed Manual

APPENDIX E: TrueFeed Quality Checklist

Date of production : …………………
Conair order number : …………………
Controller serial number : …………………
Software version : …………………
Motor serial number : …………………
Unique ID code : …………………

Check original order with internal packing list

Ordercode

:

……………………………………………………………………

Cylinder check

 Fill in the type of cylinder………
 Fill in the cylinder length………mm
 Check for cylinder wrench

Steppe

 Direction motor rotation from rear view (motor number side)
 Check if cable and connector are fastened well.
 Check sealing.

r motor check

Hopper check

 Check hopper edges for blurs
 Check lid for sharp edges
 Check slide valve
 Check sealing ring
 Check sight glasses

kpiece check

Nec

 Check sight glass and the inside if everything is clean
 Check fitting of the feeding house
 Check curled knob length and fitting

Complete un

 Perform loadcell calibration
 Perform a weight check with the 500gr reference weight
 Perform functional test with motor (200 rpm)
 Check timer and relay.
 Power cable/warning label
 Check input cable/ warning label
 Check appropriate users manual
 Check (optional) alarm flash light
 Check (optional) valve output

it check / Functional test at least 4 hours

Automatic h

 No automatic hopper loader supplied.
 ME hopper loader.
 MV hopper loader.

opper loader check (Optional)

41 Dual Feed TrueFeed Manual

APPENDIX F

We’re Here to Help

Conair has made the largest investment in customer support in the plastics industry. Our
service experts are available to help with any problem you might have installing and
operating your equipment. Your Conair sales representative also can help analyze the nature
of your problem, assuring that it did not result from misapplication or improper use.

How to Contact Customer Service

To contact Customer Service personnel, call:

NOTE: Normal operating hours are 8:00 am - 5:00 pm EST. After hours emergency

service is available at the same phone number.

Additional manuals and prints for
your Conair equipment may be
ordered through the Customer
Service or Parts Department for a
nominal fee.

From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide on-site service by contacting the Customer Service
Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses.

Before You Call...

If you do have a problem, please complete the following checklist before calling Conair:

r

r

r

r

r

r

r

Make sure you have all model, control type from the serial tag, and parts list numbers for your particular
equipment. Service personnel will need this information to assist you.

Make sure power is supplied to the equipment.

Make sure that all connectors and wires within and between control systems and related components have
been installed correctly.

Check the troubleshooting guide of this manual for a solution.

Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual
may have its own troubleshooting guide to help you.

Check that the equipment has been operated as described in this manual.

Check accompanying schematic drawings for information on special considerations.

Equipment Guarantee

Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of
shipment, against defects in material and workmanship under the normal use and service for which it was
recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s
guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The
customer assumes the cost of transportation of the part or parts to and from the factory.

Performance Warranty

Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the
equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and
maintained in the recommended manner as outlined in our quotation or specifications.

Should performance not me e t warr a nted levels, Conair at its discretion will
exercise one of the following options:

• Inspect the equipment and perform alterations or adjustments to satisfy performance claims. (Charges for such
inspections and corrections will be waived unless failure to meet warranty is due to misapplication, improper
installation, poor maintenance practices or improper operation.)

• Replace the original equ ipment with other Conair equip ment that will meet original performance claims at no
extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by the customer at which time a
Return Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned
equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is
being made.

Warranty Limitations

Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims all other
warranties with respect to the equipment, express or implied, arising by operation of law, course of dealing,
usage of trade or otherwise, including but not limited to the implied warranties o f merchantability and f itness
for a particular purpose.