ACS FRV Seroes Guide

Insert name of product insert part number • 6/12/2018 1
VERSATILE FEED ROLL
FRV SERIES
Part Number: CI0183670000EN
Revision: 07.18.2019
Revision: B
OPERATION AND INSTRUCTION MANUAL
FRV1-36, FRV1-48, FRV1-56, FRV5-56

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Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without
notice.
DCN No. ____________
© Copyright 2019 All rights reserved.

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Shipping Info
Inspecting Packaging and Equipment
Please inspect all packaging for any damage prior to unpacking. If you see any damage to
the packaging, please take pictures of the packaging prior to unpacking the equipment.
Once the pictures are taken of the packaging, take pictures of the equipment as well.
If the packaging is damaged, write Damaged Freight on the delivery receipt. If we find the
equipment is damaged, a claim can be filed.
Thoroughly check the equipment for any damage that might have occurred in transit, such
as broken or loose wiring and components, loose hardware and mounting screws, etc.
Please take pictures of the damage.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the freight claims are filed by
the terms below.
If the order is prepaid, ACS Group is responsible for the freight payment. ACS will file the
claim with the truck line. We need pictures of the damaged freight and a copy of the
delivery receipt marked Damaged Freight. ACS must be notified within 24 hours of any
damage. The driver should give you a claim number before they leave your facility.
If the order is collect or third party billing to a customer’s account, the customer is
responsible to file the claim with the truck line. You will need pictures of the damaged
freight and a copy of the delivery receipt marked Damaged Freight to file the claim. The
driver should give you a claim number before they leave your facility.
Advise customer service regarding your wish for assistance and to obtain an RMA (Return
Material Authorization) number. If you need assistance, contact the shipping supervisor at
262-641-8600.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization and,
you have received your RMA (Return Material Authorization) number from ACS.
A certified copy of our invoice is available upon request. The original Bill of Lading is
attached to our original invoice. If the shipment was prepaid and ACS is responsible for the
freight, we will submit the claim. You will need pictures of the freight, a copy of the delivery
receipt marked damaged freight and the claim number.

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If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
Machine
Bill of lading
Packing list
Operating and Installation manual
Electrical schematic and panel layout drawings
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately.
Please call 262-641-8600. Have the order number and item number available.
Hold the items until you receive shipping instructions. Do not return any goods before
receiving your RMA (Return Material Authorization) number from ACS.
Returns
Do not return any goods before receiving your RMA (Return Material Authorization)
number and shipping instructions from ACS.

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Table of Contents
CHAPTER 1: SAFETY................................................................7
1-1 How to Use This Manual ........................................................................................................... 7
Safety Symbols Used in this Manual......................................................................... 7
1-2 General Safety Regulations ....................................................................................................... 8
1-3 Responsibility ............................................................................................................................ 8
1-4 Warnings and Precautions ...................................................................................................... 11
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................13
2-1 Models Covered in This Manual.............................................................................................. 13
2-2 General Description................................................................................................................. 14
2-3 Typical Features and Components.......................................................................................... 14
2-4 Foreseeable Misuse................................................................................................................. 17
2-5 Noise Considerations............................................................................................................... 18
CHAPTER 3: INSTALLATION..................................................19
3-1 Uncrating and Installing the Equipment.................................................................................. 19
3-2 Lifting Features........................................................................................................................ 20
3-3 Electrical Connections ............................................................................................................. 20
3-4 Accessing the Rollers............................................................................................................... 22
3-5 Priming/Adjusting the Stripper Bars ....................................................................................... 23
3-6 Initial Start-up.......................................................................................................................... 24
CHAPTER 4: OPERATION.......................................................25
4-1 Start-up.................................................................................................................................... 25
4-2 Operation Procedures ............................................................................................................. 25
4-3 Air Cylinder Adjustment .......................................................................................................... 25
4-4 Adjusting the Gap Size............................................................................................................. 26
4-5 Shut-down ............................................................................................................................... 27
CHAPTER 5: MAINTENANCE..................................................28
5-1 General Maintenance Notes ................................................................................................... 28
5-2 Clearing a Jam.......................................................................................................................... 28
5-3 Replacing Stripper Bar............................................................................................................. 29
5-4 Removing the Rollers............................................................................................................... 29
5-5 Preventative Maintenance Schedule ...................................................................................... 31
5-6 Lubrication............................................................................................................................... 31

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CHAPTER 6: TROUBLESHOOTING........................................32
6-1 Introduction............................................................................................................................. 32
CHAPTER 7: APPENDIX..........................................................34
7-1 Customer Satisfaction Warranty Program .............................................................................. 34
7-2 Technical Specifications........................................................................................................... 37
7-3 Parts List and Drawings ........................................................................................................... 43
7-4 Pneumatic Circuit Diagram...................................................................................................... 46
7-5 Spare Parts List ........................................................................................................................ 47
7-6 ASME Torque Specifications.................................................................................................... 47
7-6 Technical Assistance................................................................................................................ 48

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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
machine. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the machine. We can also provide the assistance of a factory-trained technician to help train
your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the machine.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in addition
to information for operating the machine safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service. Preventive maintenance sections
are included to ensure that your machine provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available
options. A spare parts list with part numbers specific to your machine is provided with your
shipping paperwork package. Refer to this section for a listing of spare parts for purchase.
Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
CAUTION! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property
damage.

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1-2 General Safety Regulations
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by mechanical fasteners
unless the motor is electrically locked out and all moving parts are motionless.
Do not circumvent the safety interlocks.
Extreme care should be taken to see that all bolts are properly tightened at all times during the
operation of the machine.
Service personnel should observe PPE (Personal Protective Equipment) requirements for Arc
Flash per OSHA1910 and NEC70 standards.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Become familiar with materials, inspection, speed limitations, guard maintenance, and total
user responsibility while using or servicing the equipment.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. Any actual or potential
dangerous conditions must be reported to your immediate supervisor.

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Figure 1: Safety Tags and Warning Labels
Hazard Alert Symbol
Description/Explanation
Preventative Maintenance
High Voltage Hazard. The
electrical enclosure is supplied
with 3-phase electrical power.
Use caution when using or
maintaining this product.
Every six months inspect all electrical
connections for secure attachment.
For further information see the
Maintenance Chapter in this manual.
Hands could be exposed to a
crushing movement.
Every month inspect the
shear/blades for any type of wear.
For further information see the
Maintenance Chapter in this manual.
When equipped with belts and
sheaves, hands could become
entangled.
Every month inspect the belt(s) for
any type of wear. For further
information see the Maintenance
Chapter in the manual.
Hands can become entangled or
cut if they enter the danger zone
of gears or cutting shears.
Every month inspect the
shears/blades for any type of wear.
For further information see the
Maintenance Chapter in the manual.
The unit can produce continuous
noise above 85 dBA and/or
produce projectiles under normal
operating conditions.
Always wear eye and ear protection
when the machine is in operation or
performing maintenance.

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Mandatory Symbol
Description/Explanation
Read operators Manual. This equipment must be operated
and maintained by properly trained personnel. The
information contained within this manual must be read and
understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance
operations, we recommend following the local standards for
performing a lock-out/tag-out procedure. Lock out power
whenever worked on to prevent electrical shock.
Safety Gloves Required. Wear gloves to prevent injury when
performing maintenance work to avoid serious injury.
Eye & Ear protection required. This unit may produce loud
and continuous noise and may produce projectiles.
Do not reach into unit. Reaching into a unit is prohibited
while the unit is in operation and may cause serious injury.
Do not step. Stepping on the unit is prohibited and may cause
serious injury.
Do not operate the unit without guards. Operating the unit
with guards removed is prohibited and may cause serious
injury.

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1-4 Warnings and Precautions
Our machines are designed to provide safe and reliable operation when installed and operated
within design specifications, and follow national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this machine, use good judgment and follow these safe practices:
LEARN AND OBEY your company’s safety policy regarding mechanical and electrical
equipment.
MOVING OR LIFTING THE MACHINE: Although our equipment is built and engineered
for great ruggedness in operation, care must be taken when moving the machine along
the floor or lifting it. Damage may occur to sheet metal covers, electrical cabinets, or
small brackets if pressure is applied to them when moving the machine. When lifting
the machine, be certain the total machine weight does not exceed the capability of the
lifting equipment.
EQUIPMENT LOCATION: Adequate area for routine maintenance should be provided in
order to open the machine for service. Proper service area clearances also should allow
people who are working on the machine to be clearly visible to others, thereby
reducing the potential safety hazards.
SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine.
SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when servicing or
operating the machine.
EAR PROTECTION: The Occupational Safety and Health Act of 1970 has established
guidelines for Permissible Noise Exposures (OSHA 1910.95) that should be followed.
CUT RESISTANT GLOVES MUST ALWAYS BE WORN when servicing or handling knives.
NEVER attempt to operate the machine unless it is fully assembled with all guards and
interlocks in place and functional.
OBSERVE all danger, warning, caution and safety labels on the equipment.
Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS AND
COVERS are securely and properly fastened prior to resuming machine operation. All
fasteners must be in place and properly tightened. ANY SHORTCUTS MAY RESULT IN
INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.
NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should NEVER
be worn. Long hair must be tied back or placed in a tight fitting hairnet. NEVER lean
against or rest hands or feet on the equipment when it is in operation or open for
maintenance. NEVER stand on the machine when it is in operation.

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ROTATION OF MOTORS: The correct rotating direction for the machine motor is clearly
marked on the machine. Always check for proper rotation of motors. Incorrect rotation
direction can cause severe damage.
ELECTRICAL GROUNDING: All electrical equipment on the machine must be grounded
in accordance to all local codes and Article 250 of the National Electric Code.
ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the machine before
performing any service.
SAFETY INTERLOCKS MUST NOT BE BYPASSED: The mechanical and electrical safety
interlocks ensure the safety of personnel. They should never be tampered with or
removed for ANY reason. They should be checked frequently by a qualified mechanic
for proper operation.
NEVER modify the machine configuration or any individual component without written
notice from the factory.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide by
the foregoing recommendations in order to make operator safety a reality.

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Chapter 2: Functional Description
2-1 Models Covered in This Manual
Read this manual to learn how to operate and service your feed roll safely. It covers the
family of feed rolls called the Feed roll Versatile Series (FRV), with models: FRV-36, FRV1-48,
FRV1-56, and FRV5-56. This series of feed rolls designed for intermediate level jobs requiring
variable feed rate control and medium crushing force.
The difference between the FRV1-XX and FRV5-XX subseries should be noted.
•The FRV1-XX is the narrow gap feed roll. The differences from the FRV5-XX are 1)
the maximum roller gap is 1”, and 2) BOTH rollers have strippers.
•The FRV5-XX is the wide gap feed roll. The differences from the FRV1-XX are 1) the
maximum roller gap is 5”, and 2) only the fixed roll has stripper assemblies.
NOTE: This manual covers light maintenance only. No further maintenance should be
performed without first contacting the ACS Service Department at the mailing address and
phone number shown in this manual.

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When calling the factory for service information and parts, please have the model and serial
number of your machine on hand. If the feed roll has been purchased independently from
the accompanying equipment, the serial number and nameplate will be located at the feed
roll control box. If the feed roll has been purchased attached to accompanying equipment,
the feed roll shares the serial number of the accompanying equipment.
2-2 General Description
A FEED ROLL is a machine that is design to control the feed rate of sheet material.
Additionally, it may be used to crush down sheet geometry that has been raised due to
thermoforming or some other fabrication processes.
2-3 Typical Features and Components
1. 3 hp Motor
2. 14.68:1 Gear Reducer
3. Micro Adjustable Air Cylinder (x2)
4. Cover Plates (x4)
The feed rolls are positioned by two 2.5” dia. air cylinders with flow control valves to control
extension speed. Each air cylinder has an adjustable stop built into the rear of the cylinder
that can be used to limit the forward travel of the rolls to keep them from running in contact
with each other. NOTE that unlike FRV1-XX, the FRV5-XX models do NOT come with the
Micro-Adjustment air cylinders as standard; they are an available option though. See the
Section 7-1 for more details on the air cylinders.
1
2
4
3

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1. Translating Roll
2. Fixed Roll
3. Maintenance Windows (covered by
Cover Plates)
The feed rolls are constructed from carbon steel DOM (Drawn over Mandrel) tubing with a
medium knurled surface. This design provides a strong roll with good balance. Integral to each
roll head is a replaceable end ring that is designed to be slightly larger than the knurled
diameter of the roll so that, at the minimum gap, the knurled surfaces do not touch. Access to
the rolls is available via removable top and bottom cover plates. The rolls are interchangeable.
1
2
3

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1. Delrin Stripper
2. Adjustable Stripper Assembly
The strippers are used to ensure separation of sheet and roll at the exit side of the feed roll.
Each roll has a set of adjustable stripper bars made from Delrin and mounted on a carbon
steel mounting plate. The strippers serve to aid in sheet removal and will help prevent
material from wrapping the roll. The strippers are in three (3) independently adjustable
segments on each roll. Stripper adjustment is further discussed in Section 3-4.
•The pneumatic system speed is
controlled by adjustable flow control
values.
1
2
1

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The basic controls for the feed nip are an open/close valve and a filter/lubricator/regulator
set mounted on the unit. See the Chapter 4: Operation for a discussion on air pressure
settings.
The drive system uses a number 60 duplex chain synchronously by a sprocket on a flange
mounted gearbox. This style chain is allowed to stretch up to 3% before it should be
changed. The chain is 69” long; about 2” of adjustment is needed for the chain to operate
properly. This adjustment can be performed by maintenance personnel by adjusting the
take-up sprocket.
2-4 Foreseeable Misuse
To ensure safe use of the feed roll, AVOID ALL OF THE FOLLOWING. DO NOT:
•Operate feed roll outdoors.
•Operate feed roll without ALL guards and cover plates installed.
•Operate with material other than what the feed roll has been quoted for.
•Operate feed roll at an input frequency (VFD controlled) lower than 20 Hz for an extended
amount of time.

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2-5 Noise Considerations
Maximum continuous Noise Levels for the Feed Roll (5” x 56”), was recorded as follows: -
Sound Pressure (A LEQ) = 63.5 db(A), C Peak (C Pk) = 73.9 db(C). Subsequently, there is no
requirement to wear hearing protection in the vicinity of the of feed roll machines.

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Chapter 3: Installation
3-1 Uncrating and Installing the Equipment
As shipped, the feed roll and accompanying equipment are securely bolted onto skids and
covered with a wooden crate. The electrical cabinet, an optional item, is similarly packaged
when ordered.
•Remove the strapping.
•Remove the packages and parts from the skid or inner sides of the crate.
•Remove the hold-down bolts, nuts, etc.
•Inspect for damage during transit and notify the carrier immediately of any
damage.
•Check the packing list and notify ACS if there are any shortages.
The machine weights for the Versatile Feed rolls are as follows:
•FRV1-36: 975 lbs (442.3 kg)
•FRV1-48: 1100 lbs (500 kg)
•FRV1-56: 1200 lbs (544.3 kg)
•FRV5-56: 1230 lbs (557.9 kg)
REMOVE THE PROTECTIVE WRAP
The machine is shipped with a protective wrapping, which must be removed prior to start-
up. There is a thin coating of oil on exposed steel surfaces internal to the unit which can be
removed with a degreaser type liquid or solvent.

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3-2 Lifting Features
To facilitate lifting of the feed roll, each model has tapped holes for eyebolt lugs. These
holes are M12 x 1.75, and are located in the corners of the top plate, indicated by the circles
and arrows below. BEFORE LIFTING IS ATTEMPTED, ensure that all other bolts and features
are properly tightened and mated.
3-3 Electrical Connections
Before operating the feed roll or accompanying equipment, it is extremely important that a
licensed electrician correctly wires the machine into the plant power source.
All electrical equipment must be properly grounded in accordance with local and national
codes to protect personnel from electrical shock.
A fusible, lockable disconnect between the plant power source and the machine electrical
cabinet is highly recommended.
ELECTRICAL WIRING
To wire the feed roll, run power (of the proper voltage) from the plant source through a
lockable, fusible disconnect to the machine electrical control panel.
From the main electrical panel, make the necessary wiring connections to the main drive
motor.