Sterling AF-XXX Troubleshooting, Introduction, Problem Possible cause Corrective action

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Chapter 7: Troubleshooting

7-1 Introduction

The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal troubleshooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated. Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine. Be sure that the voltmeter has at least minimum impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales. Popular combination meters, VOM and VTVM can be selected to provide the necessary functions.

Before making haphazard substitutions and repairs when defective electrical components are malfunctioning, we recommend that you check the associated circuitry and assemblies for other defective devices. It is common to replace the obviously damaged component without actually locating the real cause of the trouble. Such hasty substitutions will only destroy the new component. Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When necessary, refer to the parts catalog section.

Problem	Possible cause	Corrective action

	No power to the control.	Plug in control.
	Power switch is off.	Turn power on.
	Fuse is blown.	Replace fuse.
	Auger is jammed.	Clear.
	Loose control wiring.	Tighten.
	Power switch has failed.	Replace.
	Motor switch has failed.	Replace.
Feeder will not run with switch	Feeder is wired incorrectly to	Refer to the control enclosure
Feeder will not run with switch	the processing machine.	wiring diagram.
in AUTO or MANUAL position.	Control relay has failed.	Replace.
	Motor control has failed.	Replace.
	Motor brushes are worn.	Replace.
	Controller is in the program	Reset DIP Switch 7.
	mode. Display reads PROG.
	Optional timer set incorrectly.	Reset timer.
	Optional timer mode set	Set operation mode to H and
	incorrectly.	configuration to d.
	Optional timer has failed.	Replace.

Additive Feeders

Chapter 7: Troubleshooting

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Contents SF Series Additive Feeders Shipping Information Table of Contents Program Parameter Descriptions How to Use This Manual SafetySafety Symbols Used in this Manual Wear Safety Glasses and Work Gloves General Responsibility ResponsibilityRemember Operator ResponsibilityMaintenance Responsibility Additive Feeder Safety TagsReporting a Safety Defect Models Covered in This Manual Standard FeaturesMechanical Features Functional DescriptionController Features Electrical FeaturesOptions Safety Devices and Interlocks AccessoriesSafety Device Lock-Outs Safety Circuit StandardsFail Safe Operation Rigging and Placing the Additive Feeder InstallationSupply System Installation Uncrating the EquipmentElectrical Connections Main Power ConnectionControl Relay Connection Determining the Desired Feed Rate Setup Procedures110 100 Procedure Calibration ProcedureEquipment Needed Observed Feed Rates ExamplesShutting Down the Additive Feeder Initial Start-upPre-Startup Checks Starting Up the Additive FeederStart-up Timer ModuleUsed as a Cycle Override Safety Timer OperationElapsed Time Module Counter ModuleField Control Programming Injection Molding ApplicationsInjection Molding Control Relay ConnectionJP1 Program Enable Jumper Resetting the Unit to Un-Programmed StateProgramming Step by Step Guide Additive Feeders Operation Injection Mode Application Notes Extruder Tracking Control Extrusion ApplicationsExtruder Tracking Equation Extruder Tracking Installation and SetupParameter-Selection Mode Running ModeValue Mode Resetting the Unit to Un-Programmed State Extruder Tracking Control Application Notes Input Pulse Signal RequirementsMinimum Input Pulse Rate Minimum and Maximum Percent Setpoints Maximum Input Pulse RateDefining Program Parameters Program Parameter DescriptionsMode 1 Default to Zero Parameter 19 Power-up Value Parameter 35 Signal Input 2 S2 Input Configuration Parameter 36 Signal Input 2 S2 Setpoint Preventative Maintenance Schedule MaintenancePhotocopy this page for your maintenance records Material Cleanout/Changeover Preventative MaintenanceInstalling Auger Assembly Corrective MaintenanceAuger Assembly Changeover Removing Auger AssemblyMotor Brush Replacement Problem Possible cause Corrective action TroubleshootingIntroduction Problem Possible cause Corrective action Additive Feeders Troubleshooting Appendix Technical SpecificationsAnnex B Information Additive Feeder Specifications and Overall Dimensions Drawings and DiagramsTypical Additive Feeder Controllers Exploded Assembly Drawing Parts List Spare Parts ListDetail # Part number Part/assembly description One Component Control Enclosure Parts Identification Credit Returns Safety Tag InformationWarranty Returns Returned Material PolicyCompany Logo Additive Feeder Identification Serial Number TagSterling, Inc Th Street New Berlin, WI Technical AssistanceWorksheet for Charting Feed Rates