Вы находитесь на странице: 1из 30

Training manual

FMX Loader
Feedmax A Series Loader
This training manual is copyrighted material. All rights, reserved, including those for translation, reprinting,
presentation, removal of figures and tables, transmission via radio or television, microfilming, or other means
of duplication, as well as storage in data processing systems, or any other use in whole or in parts of this
document.
Wittmann Kunststoffgerte GmbH reserves the right to make changes to any part of this training manual
without prior notice.
This training manual was carefully prepared; however, Wittmann GmbH assumes no liability for any errors or
any direct or indirect harm resulting from use of this training manual.
Nucon Wittmann FMX Series Loader

Contents
Table of Contents . . . . . . . . . . . . . .1
Introduction . . . . . . . . . . . . . . . . . .2
Features . . . . . . . . . . . . . . . . . . . . .2
Pre-Start Check . . . . . . . . . . . . . . . .2
FMX Loader Operating
Sequence (Timed) . . . . . . . . . . . . . . 3
Polytube Connections . . . . . . . . . . . 3
Demand Sensor . . . . . . . . . . . . . . . 4
Solenoid Valve . . . . . . . . . . . . . . . . 4
Compressed Air . . . . . . . . . . . . . . . 4
Recommended Air Line Size . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . 5
Basic Maintenance . . . . . . . . . . . . . 5

APPENDIX A
FMX Y Loaders . . . . . . . . . . . . . .7
FMX DPV Loaders . . . . . . . . . . . .8
FMX DPV-Y Loaders . . . . . . . . . . 9

APPENDIX B
DPV Controls . . . . . . . . . . . . 11 - 17

EXPLODED VIEWS &


BILL OF MATERIALS
FMX Dedicated . . . . . . . . . . . 20 - 21
FMX Actuated . . . . . . . . . . . 22 - 23
FMX DPV . . . . . . . . . . . . . . . 24 - 25
FMX DPV-Y . . . . . . . . . . . . . . 26 - 27
FMX Flapper . . . . . . . . . . . . . 28 - 29
1
Introduction Pre-Start Check
Your Nucon Wittmann Loader has been designed and Before starting up your system, check the following items:
assembled to give many years of trouble free service with
a minimum of maintenance. Any damage or parts missing 1. Make sure all filters are in place and orientated properly.
from your loader should be reported to Nucon Wittmann 2. Compressed air must be hooked-up to your unit and
as soon as possible. Before operating your equipment, please regulated to 70 psig.
read the manual for start-up and trouble shooting tips.
NOTE: COMPRESSED AIR SHOULD BE FREE OF OIL
AND WATER CONTAMINANTS.
3. Check all polytube and fittings for proper fit and
orientation.
Features 4. All loader latches and band clamps must be in place and
securely fastened.
Your loader is designed with the following components: 5. Modular center section gaskets (upper and lower) must
be in place.
1. A modular center section which can be easily changed
in size for increased or decreased capacity. 6. Check that sensors and solenoid valves are connected
and are securely in place.
2. Stainless steel construction for durability and long life.
7. Have material and vacuum inlet hoses connected and
3. Stainless steel screen filter that helps separate unwanted
secure using the hose clamps provided.
material fines back to the system central filter.
Any unauthorized repair may void manufacturers warranty.
4. Air actuated vacuum and discharge valves that ensure
a positive seal during operation. NOTE: WHEN INSPECTING THE LOADER, DISCONNECT
5. Loader material level proximity sensor for automatic ALL COMPRESSED AIR AND ELECTRICAL. KEEP
demand signal input. FINGERS AWAY FROM ALL MOVING PARTS.
6. 4 port 4-way solenoid valve, filter regulator assembly
used for valve actuation.

2
FMX Loader Operating Polytube Connections
Sequence (Timed) To ensure the loader polytube connections are correct,
note the following steps:
Your loader is equipped with a normally closed proximity
sensor for material level indication. As the level of material 1. The loader comes equipped with 1/8 NPT x 5/32
drops in the main holding hopper, the sensor becomes polytube quick press fittings.
uncovered, sending a signal back to the main system control.
The signal prompts the main control to start the system 2. Your loader must be connected to compressed air and set
vacuum pump and to energize the loader solenoid. In turn, at 70 psig.
this shifts the vacuum and discharge valves for loading.
Material will now convey for the duration of time programmed 3. With the loader NOT conveying, the vacuum valve
in the main control. When the loading time has elapsed, cylinder must be extended (compressed air to the rear
the loader solenoid is de-energized, shifting the vacuum port).
and discharge valves back and allowing the conveyed material
to drop into the holding hopper. After each cycle, a pause 4. The discharge valve is equipped with a spring return
time has been programmed into the control to allow cylinder, therefore, only one polytube fitting is required.
material to discharge from the loader. The loader level The fitting is located within the bolt pattern connecting
sensor will again scan to see if the material level has been the loader cone section and lower elevated mounting
maintained. If not, the process will begin again. flange together.

In a multi loader system, the input signals are addressed 5. You will notice the solenoid valve has a polytube tee
by the main control on the basis of the first signal sensed fitting. One side of the tee connects to the vacuum
and continues in order of signals received. valve cylinder, the other to the discharge valve fitting.
The rear port of the vacuum valve cylinder also connects
to the solenoid valve.

A quick orientation of the loader valve operation is to


lift the lid to one side and visually observe the cylinders
shifting. This is done by pressing the solenoid override
button located at one end of the solenoid valve.

Refer also to the exploded view attached for further


detail.

NOTE: KEEP FINGERS AWAY FROM VALVES WHEN


TESTING OR IF YOUR LOADER IS STILL ONLINE.
FINGERS CAN BECOME CAUGHT AND SEVERELY
BRUISED.

3
Demand Sensor Solenoid Valve -
4 Port 4-Way
The material level sensor used in the loader is a normally
closed capacitance type proximity switch. The switch is
Voltage: 120 V AC 24 V DC
factory set for a sensing distance of 15mm. An adjustment
Watts: 5.4 W 6W
screw located on the back of the switch will set the sensing
Currents draw: 50 mA 250 mA
distance from 5-15mm. With material absent from the front
face of the sensor, a demand signal is sent back to the main
control. A LED on the back of the switch also illuminates
when material level is low.

Compressed Air

Proximity Switch - Your FMX loader is equipped with a 4 port, 4-way


pneumatic solenoid valve c/w a pressure regulator and
Normally Closed 1/8 NPT port. The compressed air supplied to the
loader should NOT be lubricated and must be free of
excess moisture.
Polyester full threaded housing
30mm diameter The filter regulator should be set at 70 psig min. to
LED - indication for output on ensure positive valve actuation.
Adjustable sensing distance: 5-15mm
Voltage supply: 20-250 Vac, 24VDC
Output current: 500 mA continuous, 200 mA
Allowable operating temp: -13 to 158oF

Recommended Air Line Size


1/2 solid main supply air line c/w 1/2 ball valve for
Solenoid Valve quick shut off.

Maintain a flex connection (approx 3) from the solid


The solenoid vale is a port 4-way electrically actuated main supply line to the FMX loader air solenoid. The
spring off-set style, and is mounted at the base of the use of 1/4 polytube is recommended.
loader. It is used to actuate the vacuum and discharge
valves and is electrically driven by the main control
output on material demand.

4
4. Make sure that the stainless steel filter screen in the
Troubleshooting loader is secure and that no gaps appear between the
rubber seals and loader body.

1. Vacuum pump is coming on, but no material is 5. Regularly check all hoses and gear clamps to be sure
being drawn into the loader? that they are tight. A great deal of vacuum can be lost
Make sure loader has compressed air connected. through loose hoses.
Check polytube connections.
Check for open vacuum lines (on a multi-loader 6. Regularly inspect all hoses for cracks or flattened areas
system). or wear spots. If any of these things are noticed, the
Make sure central filter dump valve is closed. flex hose should be replaced. Hair line cracks are often
Check solenoid valve electrical connection. hard to detect, and could cause a severe drop in
Check for material at the pick-up point, possible performance.
air adjustment required.
Make sure loader is online at main control panel. 7. Ensure that all material pick-up points are adjusted
properly (ie: pick-up wands or vacuum trays). Too
2. No demand signal from the loader when low on much or too little air can greatly affect your
material? conveying rates.
Check sensor connection.
Try adjusting sensitivity screw on the proximity 8. Check to ensure that the channel gasket around the
switch. loader center section is providing a tight seal with the
Make sure main control selector switch is on. spinning. Heavy leakage can occur if this gasket
Check for any excess build up on or in front of the cracks or leaks for some reason. The toggle latches
sensor. should be checked for tightness and the band clamps
should be locked.
3. Loader not drawing in enough material?
Increase loader on time. 9. Inspect discharge valve for proper orientation and
Adjust material pick-up point. smooth operation.
Check for vacuum leaks.
10. Check all electrical connections on the loader.
4. Solenoid valve sticking? Proximity switch must be securely in place.
Clean spool with WD-40 spray.
Keep filter regulator bowl clean Refer to your attached unit exploded view. Proper
(oil will make valve stick). preventative maintenance of your Nucon Wittmann
loader will ensure years of trouble-free use.

Basic Maintenance for the For more information on parts and service please call:
Nucon Wittmann Inc.
Nucon Wittmann Vacuum Loader Tel: (905) 887-5355
In order to keep your Nucon Wittmann vacuum Fax: (905) 887-1162
loader in top running order, we suggest that you check
the following on a regular basis:
IMPORTANT NOTE:
1. Clean and inspect the filter regulator to ensure that ANY NUTS REMOVED FROM EQUIPMENT MUST BE
the filter bowl is clean and empty. If necessary, the REASSEMBLED WITH NON-SERVICABLE LOC-TITE. IF
filter element may need to be changed. The time THIS IS NOT FOLLOWED, DAMAGE CAN OCCUR TO
period for this check will depend on the quality of PRIMARY MACHINERY.
the compressed air.
FOR LOADERS WITH COMMON MATERIAL (Y
2. Check to ensure that the regulator is set at 70 psig.
LOADERS), DUAL PROPORTIONING LOADERS
Also check that the solenoid valve and air cylinders
(DPV LOADERS) OR COMMON MATERIAL DUAL
are operating smoothly by pressing the manual
PROPORTIONING LOADERS (DPV-Y LOADERS),
override button on the valve body.
REFER TO SUPPLEMENTAL PAGES FOLLOWING
3. Inspect the vacuum valve sealing disk and also check THIS MANUAL IN APPENDIX A.
the jam nuts for tightness.
5
6
Appendix A

Nucon Wittmann FMX Actuated Y Loaders


A common material line loader is often referred to as a Trouble Shooting
Y loader. A common material line is used to convey
plastic resin from a central location (ie. silos, surge hoppers, Refer to Trouble shooting operation previously described
dryer hoppers, gaylord boxes, etc.), to any number of in manual.
material Y loaders on the same system. Some plants have
1. Vacuum pump is coming on, but no material is
a multiple of common material lines that are used to
being drawn into the loader:
accommodate a variety of material commonly used with
the same production machinery.
Make sure material inlet sealing disc is in the
backward/closed position
Features At the same time, make sure that the other Y
loaders on the same system pulling material from
1. One material inlet c/w extended air cylinder and a
the same common material line have the material
positive seal shut-off sealing disc.
inlet sealing disc in the backward/closed position.
2. The material inlet is pneumatically controlled by the
vacuum valve assembly solenoid. Refer to your attached Check air supply adjustment sleeve at source. It
unit exploded view for proper polytube connections. might be wide open.

Check that air supply is at 70 PSI.


FMX-Y LoaderOperating Sequence
Your loader is equipped with a normally closed proximity
sensor for material level indication and a positive shut-off
material inlet. As the level of material drops in the main
holding hopper, the sensor becomes uncovered sending a
signal back to the main control. The signal prompts the
main control to start the system vacuum pump and to
energize the loader solenoid. In turn, this shifts the vacuum,
material inlet and discharge valves for loading. With the
material inlet sealing disc now in the forward/open position,
material will now convey for the duration of time
programmed in the main control. When the loading time
has elapsed, the loader solenoid is de-energized, shifting the
vacuum, material inlet and discharge valves back, allowing
the conveyed material to drop into the holding hopper. At
this stage the vacuum valve assembly isolates the loader
from the main vacuum line and the material inlet isolates
the loader from the common material line. After each cycle,
a pause time has been programmed into the control to
allow material to discharge from the loader. The loader level
sensor will again scan to see if the material level has been
maintained. If not, the process will begin again.
In a multi loader system, the input signals are addressed
by the main control on the basis of the first signal sensed
and continues in order of signals received.

7
Nucon Wittmann FMX DPV Loaders
A dual material line loader is often referred to as a FMX-DPV Loader Operating Sequence
DPV loader. A DPV loader has dual material inlets for
proportional loading of two different materials, usually Your loader is equipped with a normally closed proximity
virgin and regrind. Both material inlets have a positive sensor for material level indication and dual positive shut-off
sealing disc, but only one is in the backward/closed position material inlets. As the level of material drops in the main
when not loading. It is designed to pull one material from a holding hopper the sensor becomes uncovered, sending a
common virgin material line and the second material from signal back to the main control. The signal prompts the
a gaylord box, drum or grinder. A common material line is main control to start the system vacuum pump and to
referred to as a line that is used to convey plastic resin from energize the loader solenoid. In turn, this shifts the vacuum
a central location (ie. silos, surge hoppers, dryer hoppers, material inlets and discharge valves for loading. With one
gaylord boxes, etc.), to any number of material DPV common virgin material inlet in the backward/closed
loaders on the same system. position, material will now convey for the duration of time
programmed in the main control. During this conveying
time both material inlets will open and close, depending
Features on setting, allowing percentages of different material to be
conveyed into the loader. When the loading time has elapsed
1. Dual material inlets c/w extended air cylinders and
the loader solenoid is de-energized, shifting the vacuum,
positive seal shut-off sealing discs.
material inlets and discharge valves back allowing the
2. Both material inlets are pneumatically controlled by one conveyed material to drop into the holding hopper. At this
4 port 4-way solenoid. stage, the vacuum valve assembly isolates the loader from
3. Each DPV loader is equipped with a remote DPV the main vacuum line, the common virgin material inlet
control box allowing proportioning to be controlled at isolates the loader from the common virgin material line,
the machine (SEE APPENDIX B). Control boxes are and the second regrind material inlet remains open. After
supplied on systems using a main control panel. If the each cycle, a pause time has been programmed into the
panel includes the option for porportioning at the main control to allow material to discharge from the loader. The
control, then the DPV control box is not required. loader level sensor will again scan to see if the material
level has been maintained. If not, the process will begin
again.
FMX-DPV Loader Control
When installing a DPV loader with a standard main In a multi loader system, the input signals are addressed
control panel, the remote FMX-DPV control box is to be by the main control on the basis of the first signal sensed
wired in conjunction with the main control. Refer to and continues in order of signals received.
electrical schematic of both the main control and the
FMX-DPV control for proper wiring. All electrical components
located on the loader are wired to the remote FMX-DPV Trouble Shooting
control box and in turn the FMX-DPV control box is wired Refer to Trouble shooting operation previously described
back to the main control panel. When wiring a loader on in manual.
a system where proportioning is performed at the main
control panel, all electrical components on the loader are 1. Vacuum pump is coming on, but no material is
wired directly back to the main control and the remote being drawn into the loader:
FMX-DPV control box is not required. At the beginning of a cycle make sure the common
material inlet sealing disc is in the forward/open
position and the regrind material inlet sealing disc is
in the backward/closed position.
At the same time make sure that the other DPV
loaders on the same system pulling material from the
same common virgin material line have the correct
material inlet connected to the common virgin
material line.

8
Nucon Wittmann FMX DPV-Y Loaders
A DPV-Y loader has dual material inlets for proportional FMX-DPV Loader
loading of two different materials, usually virgin and
regrind. Both material inlets have a positive sealing disk, Operating Sequence
and are both in the backward/closed position when not Your loader is equipped with a normally closed proximity
loading. It is designed to pull one material from a common sensor for material level indication and dual positive shut-
virgin material line and the second material from a separate off material inlets. As the level of material drops in the main
common regrind material line. A common material line is holding hopper the sensor becomes uncovered, sending a
referred to as a line that is used to convey plastic resin from signal back to the main control. The signal prompts the
a central location (ie. silos, surge hoppers, dryer hoppers, main control to start the system vacuum pump and to
gaylord boxes, etc.), to any number of material DPV-Y energize the loader solenoid. In turn, this shifts the vacuum
loaders on the same system. material inlets and discharge valves for loading. With the
common virgin material inlet sealing disc now in the
forward/open position and the second regrind material inlet
Features in the backward/closed position, material will now convey
1. Dual material inlets c/w extended air cylinders and for the duration of time programmed in the main control.
positive seal shut-off sealing discs. During this conveying time both material inlets will open
2. Both material inlets are pneumatically controlled by two and close depending on setting, allowing percentages of
separate 4 port 4-way solenoid mounted on solenoid different material to be conveyed into the loader. When the
mounting brackets located on the loader base. loading time has elapsed the loader solenoid is de-energized,
shifting the vacuum, material inlets and discharge valves
3. Each DPV loader is equipped with a remote DPV back allowing the conveyed material to drop into the
control box allowing proportioning to be controlled at holding hopper. At this stage, the vacuum valve assembly
the machine (SEE APPENDIX B). Control boxes are isolates the loader from the main vacuum line and both
supplied on systems using a main control panel. If the material inlets isolate the loader from both the common
panel includes the option for porportioning at the main virgin material line, and the common regrind line. After
control, then the DPV control box is not required. each cycle a pause time has been programmed into the
Refer to your attached unit exploded view for proper control to allow material to discharge from the loader. The
polytube connections. loader level sensor will again scan to see if the material level
has been maintained. If not, the process will begin again.
In a multi loader system the input signals are addressed
DPV-Y Loader Control by the main control on the basis of the first signal sensed
When installing a DPV loader with a standard main and continues in order of signals received.
control panel, the remote FMX-DPV control box is to be
wired in conjunction with the main control. Refer to
electrical schematic of both the main control and the FMX-
Trouble Shooting
DPV control for proper wiring. All electrical components Refer to trouble shooting operation previously described
located on the loader are wired to the remote FMX-DPV in manual.
control box and in turn the FMX-DPV control box is wired 1. Vacuum pump is coming on, but no material is
back to the main control panel. When wiring a loader on a being drawn into the loader:
system where proportioning is performed at the main
At the beginning of a cycle, make sure the virgin
control panel, all electrical components on the loader are
material inlet sealing disc is in the backward/closed
wired directly back to the main control, the remote FMX-
position and the regrind material inlet sealing disc
DPV control box is not required.
is in the backward/closed position.
At the same time make sure that the other DPV-Y
loaders on the same system pulling material from
the same common material lines have the correct
material inlet connected to the correct common
virgin and regrind lines.

9
10
Appendix B

11
12
13
14
15
16
17
Advantages of Feedmax Vacuum Loaders

Pneumatic actuated Removable powder


vacuum sequencing coated, mild steel
valve. spun lid.

Detachable lid for quick,


easy access. Movable
hinge position for Stainless steel material
installation flexibility. and vacuum line size
reducers for ease of
installation and simple
Quick release toggle system retrofits.
clamps for fast,
easy access.
Stainless steel material
inlet for common
Level priority material conveying.
sequencing proximity Pneumatic actuated
switch. positive shut-off valve
for proportional
material loading.
Interchangeable
stainless steel centre
section allows for Band clamp allows
hopper capacity simple, fast
flexibility. disassembly of
modular components.
Stainless steel construction
of all material contact
surfaces prevents material
contamination and
corrosion and allows for Solid state triple
ease of cleaning. shielded capacitance
style proximity switch
to indicate material
Stainless steel hopper
demand.
mounting flange and
pneumatic actuated
discharge valve
assembly.

18
Exploded Views and Bill of Materials

FMX Series

19
20
21
22
23
24
25
26
27
28
29