Training manual

FMX Loader
Feedmax A Series Loader
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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
Your Nucon Wittmann Loader has been designed and
assembled to give many years of trouble free service with
a minimum of maintenance. Any damage or parts missing
from your loader should be reported to Nucon Wittmann
as soon as possible. Before operating your equipment, please
read the manual for start-up and trouble shooting tips.
Features
Your loader is designed with the following components:
1. A modular center section which can be easily changed
in size for increased or decreased capacity.
2. Stainless steel construction for durability and long life.
3. Stainless steel screen filter that helps separate unwanted
material fines back to the system central filter.
4. Air actuated vacuum and discharge valves that ensure
a positive seal during operation.
5. Loader material level proximity sensor for automatic
demand signal input.
6. 4 port 4-way solenoid valve, filter regulator assembly
used for valve actuation.
2
Pre-Start Check
Before starting up your system, check the following items:
1. Make sure all filters are in place and orientated properly.
2. Compressed air must be hooked-up to your unit and
regulated to 70 psig.
NOTE: COMPRESSED AIR SHOULD BE FREE OF OIL
AND WATER CONTAMINANTS.
3. Check all polytube and fittings for proper fit and
orientation.
4. All loader latches and band clamps must be in place and
securely fastened.
5. Modular center section gaskets (upper and lower) must
be in place.
6. Check that sensors and solenoid valves are connected
and are securely in place.
7. Have material and vacuum inlet hoses connected and
secure using the hose clamps provided.
Any unauthorized repair may void manufacturers warranty.
NOTE: WHEN INSPECTING THE LOADER, DISCONNECT
ALL COMPRESSED AIR AND ELECTRICAL. KEEP
FINGERS AWAY FROM ALL MOVING PARTS.
 FMX Loader Operating
Sequence (Timed)
Your loader is equipped with a normally closed proximity
sensor for material level indication. As the level of material
drops in the main holding hopper, the sensor becomes
uncovered, sending a signal back to the main system 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 and discharge valves for loading.
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
and discharge valves back and allowing the conveyed material
to drop into the holding hopper. 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.
Polytube Connections
To ensure the loader polytube connections are correct,
note the following steps:
1. The loader comes equipped with 1/8 NPT x 5/32
polytube quick press fittings.
2. Your loader must be connected to compressed air and set
at 70 psig.
3. With the loader NOT conveying, the vacuum valve
cylinder must be extended (compressed air to the rear
port).
4. The discharge valve is equipped with a spring return
cylinder, therefore, only one polytube fitting is required.
The fitting is located within the bolt pattern connecting
the loader cone section and lower elevated mounting
flange together.
5. You will notice the solenoid valve has a polytube tee
fitting. One side of the tee connects to the vacuum
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

Troubleshooting
1. Vacuum pump is coming on, but no material is
being drawn into the loader?
Make sure loader has compressed air connected.
Check polytube connections.
Check for open vacuum lines (on a multi-loader
system).
Make sure central filter dump valve is closed.
Check solenoid valve electrical connection.
Check for material at the pick-up point, possible
air adjustment required.
Make sure loader is online at main control panel.
2. No demand signal from the loader when low on
material?
Check sensor connection.
Try adjusting sensitivity screw on the proximity
switch.
Make sure main control selector switch is on.
Check for any excess build up on or in front of the
sensor.
3. Loader not drawing in enough material?
Increase loader on time.
Adjust material pick-up point.
Check for vacuum leaks.
4. Solenoid valve sticking?
Clean spool with WD-40 spray.
Keep filter regulator bowl clean
(oil will make valve stick).
Basic Maintenance for the
Nucon Wittmann Vacuum Loader
In order to keep your Nucon Wittmann vacuum
loader in top running order, we suggest that you check
the following on a regular basis:
1. Clean and inspect the filter regulator to ensure that
the filter bowl is clean and empty. If necessary, the
filter element may need to be changed. The time
period for this check will depend on the quality of
the compressed air.
2. Check to ensure that the regulator is set at 70 psig.
Also check that the solenoid valve and air cylinders
are operating smoothly by pressing the manual
override button on the valve body.
3. Inspect the vacuum valve sealing disk and also check
the jam nuts for tightness.
4. Make sure that the stainless steel filter screen in the
loader is secure and that no gaps appear between the
rubber seals and loader body.
5. Regularly check all hoses and gear clamps to be sure
that they are tight. A great deal of vacuum can be lost
through loose hoses.
6. Regularly inspect all hoses for cracks or flattened areas
or wear spots. If any of these things are noticed, the
flex hose should be replaced. Hair line cracks are often
hard to detect, and could cause a severe drop in
performance.
7. Ensure that all material pick-up points are adjusted
properly (ie: pick-up wands or vacuum trays). Too
much or too little air can greatly affect your
conveying rates.
8. Check to ensure that the channel gasket around the
loader center section is providing a tight seal with the
spinning. Heavy leakage can occur if this gasket
cracks or leaks for some reason. The toggle latches
should be checked for tightness and the band clamps
should be locked.
9. Inspect discharge valve for proper orientation and
smooth operation.
10. Check all electrical connections on the loader.
Proximity switch must be securely in place.
Refer to your attached unit exploded view. Proper
preventative maintenance of your Nucon Wittmann
loader will ensure years of trouble-free use.
For more information on parts and service please call:
Nucon Wittmann Inc.
Tel: (905) 887-5355
Fax: (905) 887-1162
IMPORTANT NOTE:
ANY NUTS REMOVED FROM EQUIPMENT MUST BE
REASSEMBLED WITH NON-SERVICABLE LOC-TITE. IF
THIS IS NOT FOLLOWED, DAMAGE CAN OCCUR TO
PRIMARY MACHINERY.
FOR LOADERS WITH COMMON MATERIAL (Y
LOADERS), DUAL PROPORTIONING LOADERS
(DPV LOADERS) OR COMMON MATERIAL DUAL
PROPORTIONING LOADERS (DPV-Y LOADERS),
REFER TO SUPPLEMENTAL PAGES FOLLOWING
THIS MANUAL IN APPENDIX A.
5
6
 Appendix A

Nucon Wittmann FMX Actuated Y Loaders

A common material line loader is often referred to as a
Y loader. A common material line is used to convey
plastic resin from a central location (ie. silos, surge hoppers,
dryer hoppers, gaylord boxes, etc.), to any number of
material Y loaders on the same system. Some plants have
a multiple of common material lines that are used to
accommodate a variety of material commonly used with
the same production machinery.
Features
1. One material inlet c/w extended air cylinder and a
positive seal shut-off sealing disc.
2. The material inlet is pneumatically controlled by the
vacuum valve assembly solenoid. Refer to your attached
unit exploded view for proper polytube connections.
Trouble Shooting
Refer to Trouble shooting operation previously described
in manual.
1. Vacuum pump is coming on, but no material is
being drawn into the loader:
Make sure material inlet sealing disc is in the
backward/closed position
At the same time, make sure that the other Y
loaders on the same system pulling material from
the same common material line have the material
inlet sealing disc in the backward/closed position.
Check air supply adjustment sleeve at source. It
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
DPV loader. A DPV loader has dual material inlets for
proportional loading of two different materials, usually
virgin and regrind. Both material inlets have a positive
sealing disc, but only one is in the backward/closed position
when not loading. It is designed to pull one material from a
common virgin material line and the second material from
a gaylord box, drum or grinder. A common material line is
referred to as a line that is used to convey plastic resin from
a central location (ie. silos, surge hoppers, dryer hoppers,
gaylord boxes, etc.), to any number of material DPV
loaders on the same system.
Features
1. Dual material inlets c/w extended air cylinders and
positive seal shut-off sealing discs.
2. Both material inlets are pneumatically controlled by one
4 port 4-way solenoid.
3. Each DPV loader is equipped with a remote DPV
control box allowing proportioning to be controlled at
the machine (SEE APPENDIX B). Control boxes are
supplied on systems using a main control panel. If the
panel includes the option for porportioning at the main
control, then the DPV control box is not required.
FMX-DPV Loader Control
When installing a DPV loader with a standard main
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-DPV control for proper wiring. All electrical components
located on the loader are wired to the remote FMX-DPV
control box and in turn the FMX-DPV control box is wired
back to the main control panel. When wiring a loader on
a system where proportioning is performed at the main
control panel, all electrical components on the loader are
wired directly back to the main control and the remote
FMX-DPV control box is not required.
8
FMX-DPV Loader Operating Sequence
Your loader is equipped with a normally closed proximity
sensor for material level indication and dual positive shut-off
material inlets. 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 inlets and discharge valves for loading. With one
common virgin material inlet in the backward/closed
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
on setting, allowing percentages of different material to be
conveyed into the loader. When the loading time has elapsed
the loader solenoid is de-energized, shifting the vacuum,
material inlets 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, the common virgin material inlet
isolates the loader from the common virgin material line,
and the second regrind material inlet remains open. 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.
Trouble Shooting
Refer to Trouble shooting operation previously described
in manual.
1. Vacuum pump is coming on, but no material is
being drawn into the loader:
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.
 Nucon Wittmann FMX DPV-Y Loaders
A DPV-Y loader has dual material inlets for proportional
loading of two different materials, usually virgin and
regrind. Both material inlets have a positive sealing disk,
and are both in the backward/closed position when not
loading. It is designed to pull one material from a common
virgin material line and the second material from a separate
common regrind material line. A common material line is
referred to as a line that is used to convey plastic resin from
a central location (ie. silos, surge hoppers, dryer hoppers,
gaylord boxes, etc.), to any number of material DPV-Y
loaders on the same system.
Features
1. Dual material inlets c/w extended air cylinders and
positive seal shut-off sealing discs.
2. Both material inlets are pneumatically controlled by two
separate 4 port 4-way solenoid mounted on solenoid
mounting brackets located on the loader base.
3. Each DPV loader is equipped with a remote DPV
control box allowing proportioning to be controlled at
the machine (SEE APPENDIX B). Control boxes are
supplied on systems using a main control panel. If the
panel includes the option for porportioning at the main
control, then the DPV control box is not required.
Refer to your attached unit exploded view for proper
polytube connections.
DPV-Y Loader Control
When installing a DPV loader with a standard main
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-
DPV control for proper wiring. All electrical components
located on the loader are wired to the remote FMX-DPV
control box and in turn the FMX-DPV control box is wired
back to the main control panel. When wiring a loader on a
system where proportioning is performed at the main
control panel, all electrical components on the loader are
wired directly back to the main control, the remote FMX-
DPV control box is not required.
FMX-DPV Loader
Operating Sequence
Your loader is equipped with a normally closed proximity
sensor for material level indication and dual positive shut-
off material inlets. 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 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
in the backward/closed 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 on setting, allowing percentages of
different material to be conveyed into the loader. When the
loading time has elapsed the loader solenoid is de-energized,
shifting the vacuum, material inlets 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 both
material inlets isolate the loader from both the common
virgin material line, and the common regrind 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.
Trouble Shooting
Refer to trouble shooting operation previously described
in manual.
1. Vacuum pump is coming on, but no material is
being drawn into the loader:
At the beginning of a cycle, make sure the virgin
material inlet sealing disc is in the backward/closed
position and the regrind material inlet sealing disc
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
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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

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