THE DRY SOLIDS METERING MECHANISMS DISCUSSED IN THIS GUIDE CONTAIN ROTATING COMPONENTS. TO AVOID POSSIBLE BODILY INJURY, POWER TO THE EQUIPMENT MUST ALWAYS BE DISCONNECTED BEFORE THE EQUIPMENT IS OPENED OR PRIOR TO PERFORMING ANY MAINTENANCE WHATSOEVER. DO NOT CLEAN WHILE OPERATING. NEVER PERMIT AN OPERATOR OR ANY PERSONNEL TO PLACE HANDS, FEET, APPAREL OR ANY OBJECT INSIDE OR NEAR THE INLET, OUTLET OR ANY FUNCTIONAL AREA OF THE EQUIPMENT WHILE POWER IS ON.
This equipment can be installed in a variety of configurations predicated on the overall process design and/or the physical equipment arrangement. It is the buyer's or user's sole responsibility to (1), define the need for and to subsequently ensure that any safety device(s) or associated safety device(s), other than that normally furnished by Acrison as standard, is provided in accordance with the specific installation and operational parameters of the equipment, and (2), define the need for and assure compliance with all applicable safety laws, rules and regulations.
If safety devices are not specifically included with the original equipment (based on the specifics of a given installation), Acrison can, at the user's expressed request only, provide whatever safety device(s) the buyer or user deems applicable. If Acrison is asked to make such recommendations prior to operation of the equipment, said recommendations are only advisory and do not impose any obligation or liability upon Acrison unless Acrison is expressly requested to provide the safety device(s), and does so.
It is the buyer's or user's sole responsibility to establish safety procedures and operational instructions to safeguard the operator(s) during maintenance, cleaning or any use of the equipment whatsoever and to subsequently ensure that the equipment is operated in conformance with all applicable safety procedures, laws, regulations and instructions. It is also the buyer's or user's sole responsibility to enforce all safety regulations and operational instructions and to maintain the equipment in a safe condition (guards in place, warning, caution and/or important labels affixed, electrical boxes secure, interlocks operational, etc.). In particular, all warning and caution labels must be maintained in a readable condition and, if necessary, replaced with new labels. These labels are available free of charge on request from Acrison.
Because the nature of the equipment does not always make it possible to prevent operator access to rotating components, under no circumstances should maintenance or cleaning be performed on the equipment without first disconnecting all power.
The equipment is supplied for the specific duty for which it was originally sold and as stipulated on the Acrison Machine Specification Sheet. It is not recommended to use this equipment for any other purpose without the expressed written consent of Acrison.
Acrison manufactures a number of different model dry solids metering mechanisms which, in their basic configuration, are identified as volumetric feeders. However, many of these model feeders (or metering mechanisms) are also utilized as the feeding mechanisms (or metering mechanisms) of Acrison's various model weigh feeders. And when used as such, the model designation of the specific model metering mechanism is also included within the weigh feeder model designation.
Designed and manufactured by Acrison, the vast majority of these metering mechanisms are auger type devices, with each individual type mechanism identified by a model number, and with each individual model mechanism possessing a specific degree of flexibility, versatility and feed-range capability. The selection of the appropriate model metering mechanism for a given application is always determined by the handling characteristics and/or feed rate of the product or products to be fed.
Please note the following model metering mechanisms manufactured by Acrison: Model Designations (metering mechanisms) - See Feeder Outline Schematics.
Models V101 and V130
Models 1015, 1015X and 1015Z
Models 105, 105X and 105Z
Models 140-0, 140-1 and 140-2
Models 170-00, 170-0, 170-1, 170-2 and 170-3
Models BDFM, BDF-1 and BDF-1.5
Models BDF-2, BDF-2.5, BDF-3, BDF-4 and BDF-5
Each of the preceding feeder models (or metering mechanisms) encompass an individual and unique mechanical design, intended to accurately and reliably meter/handle a given type and range (variety) of dry solid materials, the selection of which is based on the physical handling properties of the material.
Most importantly, however, it must be appreciated that the metering/handling of dry solid materials remains far more of an art than a science. And because of this, a user of dry solids metering (feeding) equipment usually initially relies on the experience and expertise of the selected manufacturer for the proper equipment model/type, and afterwards, for comprehensive long-term operational support.
Aside from mechanical difficulties which may arise, and which are usually easy to define and/or correct, difficulties associated with the physical metering/handling of a given dry solid material usually represent an entirely different situation, which is where the experience and expertise of the selected supplier plays a most significant role. Certainly, users do not desire to have their processes or plants become developmental centers for a supplier who lacks sufficient background and/or expertise in the highly specialized field of dry solids metering/handling.
In selecting Acrison equipment to satisfy your dry solids metering needs, an unparalleled degree of expertise is at your immediate disposal, should the need arise. With tens of thousands of dry solids feeders (both volumetric and gravimetric) in worldwide service in every imaginable application/industry metering virtually every imaginable dry solid ingredient, should any type of difficulty arise, Acrison's Field Service Department is at your disposal to promptly remedy any operational problems which may occur with respect to the metering of the product or products for which the equipment was sold.
The following Troubleshooting Guide is intended to assist in locating and/or identifying operational problems specifically relating to an Acrison Metering Mechanism, whether operating as a volumetric feeder or as the metering mechanism of an Acrison weigh feeder.
|Feeder motor does not operate.||D, E, F, G, H, BB|
|Feeder motor overloads with product in feeder (feeder filled).||C, D, G, H, I, M, T, W, Z, CC, DD, FF, LL, OO, PP, RR|
|Feeder motor overloads without product in feeder (feeder empty).||C, D, G, H, I, K, RR|
|Feeder augers/agitator(s) are not operating or are overloaded (applicable to the Model BDF-2, BDF-2.5, BDF-3, BDF-4, BDF-5, 170-0, 170-1 and 170-2 Metering Mechanisms).||C, D, E, F, G, I, T, V, AA, CC, DD, GG, RR|
|Feeder Intromitter, agitator or conditioning auger/agitators are not operating or are overloaded (applicable to the Model BDFM, BDF-1, BDF-1.5, 105, 105X, 105Z, 1015, 1015X, 1015Z, 120, 140-0, 140-1 and 140-2 Metering Mechanisms), although the metering auger operates.||K, RR|
|Feeder motor operates but the metering auger, intromitter, agitator, augers/agitators do not operate.||I, RR, DDD|
|Feeder motor operating but the metering auger does not rotate.||I, U, HH, II, DDD|
|Feeder not feeding even though the metering auger is rotating and the feeder is filled with product.||J, K, M, T, U, V, CC, HH, NN|
|Motor speed fluctuates.||B, C, D, G, H, K, O, P, V, Z, AA, CC, BB, DD, FF, GG, HH, OO, PP, RR|
|Material flushes uncontrollably through feeder.||T, CC, JJ, KK, MM, SS|
|Material pulsing abnormally as it discharges from the discharge cylinder of the feeder.||A, B, H, J, W, Y, CC, EE, HH, OO, TT|
|Material extruding out of discharge cylinder.||M, W, CC, HH, LL, OO, TT|
|Material leaking out of the seal(s) of the metering mechanism.||N, CC, JJ, KK, UU|
|Gears in dissimilar speed multiple auger or auger/agitator gearbox wearing and/or breaking (applicable to the Model 105, 105X, 105Z, 1015, 1015X, 1015Z, 120, 140-0, 140-1, 140-2, BDFM, BDF-1 and BFD-1.5 Metering Mechanisms).||C, K, T, W, AA, CC, DD, GG, DDD|
|Metering performance not within the accuracy specified by Acrison. Metering accuracy and/or feed rate may be erratic.||A, B, C, D, G, H, J, K, M, N, O, P, Q, R, S, T, V, W, Z, AA, BB, CC, DD, FF, GG, HH, JJ, KK, LL, MM, NN, OO, PP, QQ, RR, SS, TT|
|Feed rate cannot be achieved.||A, B, C, H, J, M, R, S, T, V, W, X, Z, AA, CC, EE, FF, GG, HH, LL, NN, OO, QQ, TT|
|Feed output gradually decreases for a given motor speed setting or feed rate selection.||A, B, C, D, H, J, M, N, P, Q, R, S, T, V, W, Z, AA, CC, EE, FF, GG, LL, OO, QQ, TT, DDD|
|Discharge cylinder warm to the touch.||M, T, Z, CC, FF, HH, LL, OO, PP, TT|
|Product adhering to the inside of the discharge cylinder.||CC, FF, LL, OO, PP, VV|
|Discharge cylinder difficult to remove; tight onto the metering auger (can be very tight).||M, T, Z, CC, FF, HH, LL, OO, PP, TT|
|Discharge cylinder (usually extended length) wobbles as the metering auger rotates.||Z, CC, HH, II, OO, PP, TT, ZZ|
|Metering auger coils-back into the feed chamber and is permanently damaged (helical type auger).||C, M, T, Z, CC, DD, FF, LL, NN, OO, PP, TT, VV|
|Metering auger breaks (usually a helical type auger, but can also be a small size solid flight type).||C, M, T, Z, CC, DD, HH, II, LL, OO, PP, TT, VV, ZZ|
|Product adhering to the metering auger causing a decreasing feed rate output for a given motor speed setting or feed rate selection (could possibly reduce the feed rate output to the point where the desired feed rate cannot any longer be achieved, and/or cause poor metering accuracy).||CC, LL, OO, WW|
|Metering auger jams.||C, M, T, W, Z, AA, CC, FF, GG, HH, II, LL, NN, OO, PP, TT, VV, WW|
|Metering auger unwinds (disconnects itself) from its drive shaft.||U|
|Metering auger noisy as it rotates.||C, M, T, Z, CC, FF, HH, II, PP|
|Metering auger difficult to remove (unthread) from its drive shaft.||XX, AAA, BBB|
|Metering auger drive shaft breaks.||Z, AA, FF, GG, HH, II, PP, ZZ, DDD|
|Material bridging/rat-holing in feeder's supply hopper (material not flowing properly from within the feeder's integral supply hopper furnished by Acrison).||A, J, N, R, T, V, CC, DD, JJ, NN, QQ, WW|
|Feeder hopper does not vibrate (applicable to the Model V1013, V101, V130, 170-00, 170-0, 170-1 and 170-2 Metering Mechanisms).||E, F, R, QQ, CCC|
|Feeder trough does not vibrate (applicable to the Model V1013, V101 and V130 Metering Mechanisms).||E, F, R, QQ, CCC|
|Feeder hopper does not oscillate (applicable to the Model 120 and certain Model 140 Metering Mechanisms).||E, F, G, YY|
|Gear-reducer leaking oil.||EEE|
|A||Bulk density fluctuations (could be caused by moisture content variations, particle size changes, or variations in the physical condition of the material, i.e., aerated, agglomerated or compacted material).|
|B||Material flowing sporadically or unreliably into the metering mechanism.|
|C||Foreign object lodged within the metering mechanism. Check the metering auger, Intromitter or agitators for obstructions to rotation.|
|D||A problem exists with power to the motor and/or variable speed controller.|
|E||Circuit breaker tripped (need to identify reason).|
|F||Fuse failure (need to identify reason).|
|G||Faulty drive motor.|
|H||Faulty variable speed controller.|
|I||Problem exists with the gear-reducer onto which the motor attaches, or with the attachment of the motor onto the gear-reducer.|
|J||Intromitter or augers/agitator(s) not rotating. If not jammed by some foreign object, check the dissimilar speed gearbox for some type of difficulty.|
|K||The reason for gears within an Acrison dissimilar speed gearbox to wear and/or break is typically due to overloading, a previous jam-up (or reoccurring jam-ups), insufficient or improper lubrication, or dirt/dust entering the gearbox (a seal failure on the metering auger drive shaft or pressure within the feeder could cause material to enter the gearbox through the double drive shaft, applicable to the double concentric drive mechanisms of the Models 105, 105X, 105Z, 120, 140-0, 140-1 and 140-2 Feeders.|
|L||Supply of material depleted.|
|M||Product adhering onto the metering auger or onto the inside of the discharge cylinder. Product adhesion onto the metering auger could also possibly cause a complete cessation of feed, particularly where smaller size metering augers are concerned.|
|N||A positive and/or negative pressure exists on either the inlet and/or outlet of the feeder, particularly problematic where weigh feeders are concerned.|
|O||If the metering mechanism of a weigh feeder, this situation could be caused by an external feed rate input setting that is unstable or changing rapidly.|
|P||If the metering mechanism of a weigh feeder, this situation could be caused by a fault or incorrect setting associated with the actual weighing system (scale).|
|Q||If the metering mechanism of a weigh feeder, this situation could be caused by a fault or incorrect setting associated with the feeder's variable speed drive.|
|R||Hopper vibration setting improper (applicable to the Model V1013, V101, V130, 170-0, 170-1 and 170-2 Metering Mechanisms).|
|S||Feed chamber vibration setting improper (applicable to the Model V1013, V101 and V130 Metering Mechanisms).|
|T||Product may be unsuitable for the particular model metering mechanism being used, if different than that which was originally specified.|
|U||Incorrect metering auger rotation.|
|V||Bin Discharger augers/agitators rotating in the incorrect direction (applicable to the Model BDF-2, BDF-2.5, BDF-3, BDF-4 and BDF-5 Metering Mechanisms).|
|W||Excessive packing of material in the feed chamber of the metering mechanism, very possibly due to the manner in which product is supplied to the metering mechanism.|
|X||Metering auger too small to achieve the required feed rate.|
|Y||Metering auger too large for the required feed rate.|
|Z||Material caked (hardened) within the inside of the discharge cylinder.|
|AA||Material compacted (hardened) within the body of the Bin Discharger.|
|BB||Problem with tachometer (when applicable).|
|CC||Product characteristics differ from that which was originally specified and from that which the metering mechanism (and its integral supply hopper supplied by Acrison - when applicable) was configured to handle.|
|DD||Product bulk density differs from that which was originally specified (more than 5 to 10 percent, for example) and from that which the metering mechanism was configured to handle.|
|EE||Product bulk density differs from that which was originally specified (more than 5 to 10 percent, for example) and from that which was used to size the metering auger.|
|FF||Product back-up at the discharge of the metering auger.|
|GG||Product caked or hardened within the feed chamber of the metering mechanism.|
|HH||Metering auger is bent or damaged.|
|II||Metering auger drive shaft is bent or damaged. (This would most be likely due to the improper removal and/or installation of a metering auger, especially a solid flight type auger having an extended length, or a helical auger with a thru-shaft, also having an extended length. Also, a misaligned discharge cylinder can cause the metering auger drive shaft to break, especially when the metering mechanism is equipped with a metering auger having an end-bearing support).|
|JJ||Pressurization of the metering mechanism through its hopper.|
|KK||Product aerated to an unacceptable level for proper metering.|
|LL||Moisture entering the discharge area of the metering mechanism causing product to adhere, cake and/or harden onto or about the end of the metering auger and discharge cylinder. Such moisture may also infiltrate into the discharge cylinder causing material to cake and harden within the inside of the discharge cylinder and/or onto the metering auger.|
|MM||Metering mechanism is discharging into a negative air stream.|
|NN||Metering mechanism is discharging into a positive air stream.|
|OO||Product is conveying abnormally through the metering auger/discharge cylinder (usually applies to an extended length metering auger/discharge cylinder).|
|PP||Improper clearance within the discharge cylinder (between the ID of the discharge cylinder and the OD of the metering auger).|
|Faulty hopper and/or feed chamber vibrator motor (when applicable).|
|RR||Intromitter, agitator or augers/agitators bent or damaged, possibly rubbing the inside of the feed chamber or Bin Discharger body.|
|SS||An empty metering mechanism is filled with product that aerates easily, flushing through the unit. An auger type metering mechanism will not act as a valve under such circumstances and therefore, measures must be taken to prevent such an occurrence.|
|TT||Material is compacting within the metering auger as it feeds. This could be due to the manner in which the metering auger is being 'filled' with product within the feed chamber or Bin Discharger body of the metering mechanism. Or, this condition may be due to the characteristics of the product being fed.|
|UU||Depending upon the model metering mechanism, a seal(s) can be either worn or require adjustment. Please refer to the specific Operating and Instruction Manual for the particular model metering mechanism (feeder).|
|VV||The inside of the discharge cylinder does not include the proper surface finish and/or coating to restrict the material from adhering to it.|
|WW||The material being fed possesses unanticipated adhesive characteristics and therefore, the metering auger and/or the feeder's integral supply hopper (furnished by Acrison) may not include the type of finish and/or coating that will reduce or eliminate such adhesion.|
|XX||Metering auger overloaded or jammed causing it to tighten onto its threaded drive shaft.|
|YY||A problem exists with the eccentric drive mechanism of the feeder's RP (oscillating) Hopper (i.e., the gear-reducer and/or its drive motor and drive belt).|
|ZZ||The discharge cylinder was somehow damaged and is no longer aligned properly with the metering auger drive shaft (i.e., the discharge cylinder is not square with its attachment plate and/or with the front plate of the feed chamber,). This type of situation can also cause the metering auger and/or its drive shaft to fail.|
|AAA||The threads of the metering auger drive shaft are damaged.|
|BBB||The metering auger is not being turned in the correct rotation for removal. (The metering auger is equipped with a left-hand threaded connection to its drive shaft; to remove, rotate clockwise.)|
|CCC||Faulty vibrator controller.|
|DDD||Coupling not attached or tightened properly (for feeders equipped with torque limiter couplings and/or mechanical drives).|
|EEE||Seals worn; paint on shaft where the seal seats; seal material is non-compatible with the plant environment and/or the material being fed, or the seal was somehow damaged.|