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Batch Blender User Manual

1. FIRST ANGLE PROJECTION FRAME BODY B 2660 z SE NUS l SCREW BEARING 20617 2 Z MIXING CHAMBER EIS T LITRE HOPPER ASSEMBLY MOTOR SPACER E MOTOR GUARD 2102 SWITCH 5714 2963 ees DOOR SWITCH 571 KEY 7963 d T DOOR ASSEMBLY IT Qu SEM m BRACKET ASSEMBLY 2973 LO 1 LOADER TDP BRALKETZ97560WOG 3 l 2 0 NECK ADAPTOR FLANGE 3 151 17 MIXING CHAMBER RETAINER SCREW COUPLING LOADCELL BLOCK LOAD CELL SPLI 36 CELL BRACKET 3161 LOADCELL GLAND PLATE 3166 8 CONSOLE BRACKET 07 07 CONSOLE ASSEMBLY VALVE BLOCK FILTER REGULATOR m aL E ENG WEIGH HOPPER FLAP 219 379 DOOR ACRYL 7 MOTOR COVER 3158 B9 NU TEL LITRE SLIDE BASEPLATE 27 HOPPER SLIDE 2650 B HOPPER CLEAR ACRYLICSOSE HOPPER SLIDE GUIDE 281 HOPPER CYLINDER Ea MOTOR SPRING PIN 3156 7724 COUPLING SPRING PIN 3757 33 WEIGH HOPPER ASSEMBLY 315 E _ 739 Li m e Pe LOADER TOP 5 06 PISTON RESTRICTOR 3516 WEIGH HOPPER FLAP EXP REV A7 Created on 01 05 2014 Maintenance TSM Material Low level sensor option CONN3 For Unused Connectors Fit Link Between Pins 1 amp 3 B Low Level Sensor Interface Link Settings FOR 11 18 Repeat For Sensors 4 8 As Needed Colors Relate Sensors Normaty Used By TSM l e IFM REV A7 Created
2. E Touch the icon to open the license screen You will need to call TSM to Software ID 2304 get a new license code but you will need to know the Software ID in order to get the new license code License Key 0 4 5 Vi P iz H MI IF a When you get a license code from TSM touch the XJ Icon to open the keypad Enter the license code then touch the save icon to save the license The option should then have a beside it to show that is enabled REV A6 Created on 01 05 2014 Page 23 Software Update TS M To update the blender software you will have to copy the new software version onto the Blender SD card To do this ESAT N E On ma 500 I Touch the Fig1 Warning The SD card must be disabled before being removed FIG 1 2 The information screen will open FIG 2 This icon will be shown if the SD card 15 in position F slon F A lip THY vnu 4 3 Touching E allows the SD card to be safely HN dugapun eee mans T IP removed When the icon turns red The TES rper SD card is safe to remove The safe mode Riese osten will time out after 30 seconds It is not necessary to do this when putting the SD card back in FIG 2 4 Move the SD card cover to one side then push the SD card and it will pop out 5 Copy the unzipped swupdate S19 and newsoft s19 files onto the SD card 6 Retur
3. 3 MT 5 MT 5 MT 6 MT 7 MT 8 MT 11 MT 12 MT 13 MT 14 MT 15 Table Of Contents Appendix Customer service Control Console over view Hemoving the control console Control console connections Connecting a side feeder European 3 phase connections U S A 3 phase connections Control console wiring overview Control console P S U drawing TSM350 650 Easy drain part identification TSM Optimix part identification Low level sensor interface optional Software update Updating the blender software Updating the touch panel software MT 21 23 24 25 26 27 28 29 30 31 32 33 Introduction TS Batch Blender Purpose of the user guide 2 Your responsibilities as a user IN 3 How to use the lockout device IN 5 REV A6 Created on 01 05 2014 Page 1 Introduction TS Batch Blender Purpose of the manual It contains important instructions on the correct operative and maintenance of the blender Follow these instructions to avoid dangers to prevent expensive down time and to increase the service life of the blender The manual must be kept for referral with the blender at its place of use The manual must also accompany the blender if it is rented or sold It is directed to people who operate and repair the blender and must be read understood and used by every person who is responsible for the following work with the blender Transpo
4. Suitable blenders and adaptors are optional listed on previous page Suitable for 75 amp 100mm outlet only Introduction TSM Batch Blender Blender Element check list Reservoir Bin Blender Frame Operator touch screen Fig 1 3 E 4 Fig 1 1 ga Example of Standard Micro dose feeder NBB batch optional electronics Console e following chart shows all parts available for the Sigmabatch range of blenders x x Optimix Optimix Optimix Optimix Optimix x Optimix 3000 x 50 150 250 350 650 100 Optimix 1500 x Blender Frame Complete x x x x x x x Reservoir bin control cabinet included J Weigh Hopper 0 9 9 9 9 9 x Operator Touch panel x x x x x x x Mfg tI 0 ooo 14 ArGun 9 9 9 Manul 02 0 9 9 9 SideFeedAuger Bin e e e e e SE e Line speed Encoder gt e e gt o e OffineKit e e e e o e Offline Stand gt e e e e Offline Bin e e e 0 Supplied as standard e Optional extra s HEV A6 Created on 01 05 2014 Page 15 Introduction Batch Blender Mounting Equipment Lifting hook in SHIPPING position 1 Gently remove the Batch Blender from the box using the lifting hooks provided on the top of the blender fra
5. the loadcell readings How dolknow if Place a known weight e g 1kg 2 lbs in the button and enter the password the blender load weigh hopper cell is calibrated The weight will be displayed on the hopper correctly calibration page see above on how to get to this page If weight Calibrate the load cell for more a more detailed calibration is explanation see the quick start section incorrect what Tare the hopper as above do do Place a known weight e g 1kg in the weigh hopper Enter the value of the known weight The blender automatically recalibrates and the actual weight should now be displayed correctly Touch to exit to main page If the Weight MeasurementiS Please check quick start guide FAQ section not functioning properly what should do am having problems with th Please check quick start guide FAQ section loadcell REV A7 Created on 01 05 2014 Page 16 Maintenance TSM Frequentl Other Accuracy issues A q y When feeding When the TSM blender leaves the factory it is set SKE through the to a standard slide valve configuration unless Questions SLIDE VALVES specified otherwise by the customer My blender does u not seem to be slide valve size determines the minimum achieving the and maximum percentages that can be metered required accuracy for each individual component See introduction section page 20 for standard sl
6. Run the blender self test Select print options Update blender software Backup blender configuration Reload blender configuration Blender communications Good Transmit Tx This indicates the number of messages transmitted Good Receive Rx This indicates the number of messages received Checksum Error C Sum This indicates that the selected unit received the response but the checksum was incorrect when the complete message was received Timeout This indicates the number of times that the unit was transmitted to and received no response The counters are displayed for the Remote display Network and the SEI It is possible to reset the communications counters at any time by touching reset If you have more than 109 errors in the communications then there is something wrong with the comms RP Remote operator panel SEI This is the card used for extrusion control Optional LLS This is the card used to read in the level sensors in the material bin Optional VAC81 2 3 These cards are used to control the vacuum loaders when using integrated loading TCP IP This option monitors is the communications if the blender is on the factory network REV A6 Created on 01 05 2014 Page 13 User manual TSM Batch Blender Da Printing Saving report options to a USB drive Use the to enable disable the following options Enableprintor Qh save to USB stick gt jen
7. 3 10 0 100 75mm None 4 10 0 100 75mm None 5 10 0 100 75mm None 6 10 0 100 75mm None 7 10 0 100 75mm None 8 10 0 100 75mm None If medium insert 0 2 15 75mm Medium 50 mm Is used If small insertis 0 1 15 Small 25 mm used REV A6 Created on 01 05 2014 Page 20 Batch Blender Introduction TSM Batch Blender General wiring considerations Full Wiring Diagrams are provided in TSM BATCH BLENDER USER MANUAL maintenance section The wires connecting the various elements of a TSM system are normally communications data lines and are low voltage As such care should be taken to keep them well removed from high voltage lines Do not run high and low voltage lines together within the same conduit Shielded cable must be used for communications lines Although it is not strictly necessary to run communications wires from TSM equipment in conduit it is desirable from a safety and aesthetic point of view Moving plastic granules can produce extreme static charges leading to malfunction Therefore do not attach communications cables to material conveying lines other conduit containing cables with high voltages high currents If possible the communications lines should be run in armoured trunking that is properly earthed grounded at one end only Flexible tubing with a ground wire must be used for all conveying lines Keep all communication lines well removed from vacuum l
8. Please check extrusion control Extrusion control control is not section page 11 working what should check havinga Please check extrusion control extrusion control problem with section page 12 line speed What should do REV A7 Created on 01 05 2014 Page 20 Maintenance Appendix Customer service Page 21 Control Console over view Page 22 Removing the control console Page 23 Control console connections Page 24 European phase connections Page 25 U S A 3 phase connections Page 26 Control console wiring overview Page 27 Control console P S U drawing Page 28 Optimix 350 650 Easy drain part identification Page 29 Optimix 50 150 250 part identification Page 30 Operator panel firmware upgrade cable Page 31 ow level sensor interface optional Page 32 otatement on TSM remote service capability of blender NBB module Hemote access Each T SM blender includes an integral Ethernet port which allows remote access by customer or other authorized personnel This service level allows the user to access all blender functions available via the operator panel including supervisor and engineering fields Assuming that the user is an authorized password holder TSM can provide remote support including configuration and software updates using this Ethernet port across the internet without any firewall configuration changes required on the customer s network upon request by the cus
9. Swap any 2 phases e g L1 amp L2 going to the blender Reconnect mains power and turn mains power switch to On Check that the rotation of the Mixing is correct in a clockwise direction when looking at the shaft of the motor from the motor end conveying material to the center of the chamber Check whether stop pause icon is displayed on the top right of the home screen Ensure that the door of the mixing chamber is properly closed Check that the system is not in PAUSE mode Check status of the appropriate LED indicator on the NBB PCB The LED should be on when valve is open page 25 for LED description Ensure that the factory air supply is connected TSM recommend air supply of 7 5 bar for optimum blender efficiency air supply pressure greater than 10 bar could damage the blender The supply must be oil free Check that air pressure on the pressure regulator gauge reads 7 5 Bar This gauge is located at the side of blender control console HEV A7 Created on 01 05 2014 Frequently Asked Questions Page 18 Maintenance If the Micradose Feeder is not operating Fill Valves have problems with the fill valves If the slide valves are not operating Other issues What version of software am operating Accuracy Problems TSM Ensure 24v cable is securely connected in the correct socket of the NBB module in the control cabinet Ensure that the door of the mixing chamber is properly
10. VOLTAGE LINES TOGETHER WITHIN THE SAME CONDUIT shielded cable must be used for communications lines Although it is not strictly necessary to run communications wires from TSM equipment in conduit it is advisable from a safety and aesthetic point of view Moving plastic granules can produce extreme static charges If pipes carrying the granules are not properly earthed then the electrical energy will be discharged down through the system electronics causing possible malfunction and damage Generally static symptoms include the resetting of the Remote Display or granules sticking to the sides of the hopper or the mixing chamber Therefore do not attach communications cables to material conveying lines other conduit containing cables with high voltages or high currents If possible run the communications lines in armoured trunking which is properly earthed grounded at one end only All conveying lines MUST BE made of flexible tubing and fitted with a ground wire HEV A7 Created on 01 05 2014 Frequently Asked Questions Page 15 Maintenance TSM Loadcell Weighing Accuracy Issues Frequ ently How dolcleara Tare the blender for more a more detailed Tare alarm tare explanation see the quick start section page 1 2 Asked the blender Ensure that mixing chamber door Questions hopper is open Touch the Select the blender type Tare the hopper by touching amp This now becomes the zero reference point for
11. e e SDcardAlam 8 8 315 None The File Allocation Table cannot be set up on the SD card The SD card needs to be re formatted or replaced HEV 9 Created on 01 05 2014 Page 8 User manual TSM Batch Blender Operator Touch screen Panel The blender operator panel may be used to A View production data B Calibrate the blender C Enter material recipes D Download recipes from optional TSM ICS central control system E Print reports Home button Mode icon Jumps back to this Shows if the screen from any Bender e th other screen otopped Paused Set and actual percentage for each component REV A6 Created on 01 05 2014 Page 1 User manual TSM Batch Blender Home screen The Touch Screen operator panel provides easy access to all parts of the SigmaBatch Blender menu structure Touch to enter recipe name component percentages and job number Displays the cause of an alarm and the time at which it occurred Displays various reports generated by the system This menu contains all the necessary blender calibration and configuration options It is password protected so only authorised personnel can access any of the calibration sub menus From this menu it is possible to start pause or halt the blending process Password Setting TSM blenders include 3 levels of password protection Engineer Password Default 9335 This allows access to the blender config
12. hazard Always disconnect and lock out the main power supply before opening the blender electrical enclosure Troubleshooting procedures that require access to the electrical enclosure while power is on should be performed only by qualified electrical technicians who know how to use electrical testing equipment and understand the hazards involved REV A7 Created on 01 05 2014 Batch Blender Page 5 Maintenance TSM Batch Blender Determining the Cause of a Problem Blender alarms Most problems will trigger one of the blender alarms The blender includes alarm checks for A Individual components B Blender system alarms If an alarm occurs on the blender Will appear on the blender bin and the red beacon mounted on the blender frame will provide a visual warning If itis a component fill alarm the blender will continue to operate in automatic mode If the alarm applies to more than one component the blender automatically enters manual mode e To find the cause of an alarm go to the production summary screen and touch 88 The cause of the alarm and the time that it occurred will be displayed on the Alarm Summary screen Touch E to cancel an alarm For information on what each alarm icon means refer to the diagnostic tables on the following pages NOTE If you are using the blender with extrusion control please see the extrusion control section of the manual for all related alarms HEV
13. manual TSM Batch Blender EN Updating the blender firmware and backing up the blender configuration The SD card is in position The SD card is missing a Configuration options i e 5 d CE E config tx d pE ne Y 1 Save the blender configuration to the SD card gt bak 2 Save a backup of the configuration to the SD card 3 go contis CERE 3 Load the configuration from the SD card 3 4 config 5 Load the backup from the SD Updating blender software See software update section 6 Qm euupcdoate zi2 E 6 Load the new software version from the SD card WARNING Before removing the SD card you must open the I screen and touch the E Saving to the SD card is suspended so it is safe to remove the SD card Do not remove the SD card the blender may be saving information to the SD card REV A6 Created on 01 05 2014 Page 18 User manual H5 Integrated Loading Batch Blender Please see the integrated loading section of this manual if your blender has been configured to operate with integrated loading REV A6 Created on 01 05 2014 Page 19 User manual Batch Blender This section is used by TSM personnel and is protected by another password to stop unauthorised personnel from changing the blender settings TSM should be consulted if any changes are needed in this section TSM Engineer La
14. operated as described in this manual 1 Check that all connections comply completely with accompanying schematic drawings and ensure that all precautions listed are satisfied A7 Created on 01 05 2014 Customer Service Here to Help How to Contact Customer Service Before You Contact Us Additional manuals and prints for your TSM equipment may be ordered through the Customer Service or Parts Departments for a nominal fee Page 22 Maintenance TSM NBB Console External Connections Blender Mains Single phase Mains Power Switch connection indicator Mains fuse 5 Connection to Blender Motor single phase only 1 6A 220v 4A 110vac 5TT 20mm Fuse for mixing motor Single phase only Mains power input socket SD Memory Card Ethernet cable port USB Memory Stick port Operator panel Printer USB port connection m Page 23 HEV A7 Created on 01 05 2014 Maintenance TSM Removing the Blender control console The TSM blender has been designed in such a way that all of the electronics parts are modularized This allows them to be easily exchanged if a problem occurs The 3 main electronic parts are 1 The electronics control console control board and power supply 2 he operator panel 3 The Electrical Contactor box 3 phase blenders only If the blender develops a problem and it is necessary to change the control console it can be do
15. out after 30 seconds as SES re It is not necessary to do this when putting the SD card back in FIG 2 4 Move the SD card cover to one side then push the SD card and it will pop out 5 Now the SD card can be put into a card reader where the contents can be read 6 log files are labelled lgyymmdd where yy is the year mm is the month and dd is the date For example 1g120210 is the log for 10 Feb 2012 Evtn1202 1s the event log for February 2012 5 1 Maintenance Batch Blender Maintenance Maintenance schedule Page 1 Cleaning the blender Page 2 Foreword You can avoid most problems by following the recommended installation operation and maintenance procedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and how to fix it Blender Cleaning When you change materials To prevent contamination of subsequent batches you should clean all bins and chambers thoroughly Drain the material bins weigh hopper and mix chamber Remove any residual material The mixing auger can also be easily removed If you are using feeders to add material or colorant you need to clean these feeders before filling them with different materials Drain the feeder bin remove the auger and using compressed air clean out any residual material Weekly or as required Inspect A Air regulator filters for condensation or other signs of water Purge and c
16. wheel is provided weight per length control Z N Mount the SEI module inside the extruder control cabinet it is desirable to have it mounted close to the drive so the 0 10 signal is not affected by noise Connect the SEI Conn1 to conn3 of the NBB board in the blender electronics console using an 8 core shielded cable Recommended cat 5E multi core Connect the Ov and the 0 10 volts output from the SEI card Conn12 to the drive controlling the extruder screw Also connect a back up potentiometer and changeover switch This will allow the user to switch to manual control of the extruder using the potentiometer in the event of problems of any kind A start up relay normally open contacts is provided and should be wired in series with the extruder momentary ON switch This prevents the extruder from being started when a large setpoint voltage is applied to the extruder drive The relay contacts will close only when the output voltage is reduced below 596 using the manual decrease icons on the blender Connect Remote Increase Decrease Auto Manual switches to CONN 9 if required There are also a 24v outputs on Conn 10 for each of these switches that can be used to turn on a led or bulb the maximum output for each output is 50mA 2 watts option it should be mounted close to the winder on a film driven roller The mounting bracket should be positioned C225 securely to ensure no movement as the roller rotates Line speed
17. 0Hz 4 5A 110v Neutral Earth 2 5A 220v Connect power to the blender If the 3 mains voltage available is greater then 440 VAC then an additional single phase supply is required as per USA wiring shown in the Maintenance section The single phase power The single phase power is wired into the connector on the side of the NBB electronics enclosure There is approximately 3 meter IEC cable supplied with the blender and the colors are shown below x Live x Brown x x Earth x Yellow green x REV A6 Created on 01 05 2014 Page 17 Batch Blender Introduction Connecting Oil Free Air Supply e Connect oil free compressed air supply to the blender The regulator is set at 7 5 bar 110 P S I e European 8 mm push fit pipe USA inch push fit pipe Set the air pressure as follows Connect compressed air supply by inserting piping into available port on regulator e Pull cap upwards to unlock e Twist cap in a clockwise direction to increase the pressure e When the correct pressure is set push the cap back down to secure e he water trap needs to be checked regularly and drained accordingly HEV A6 Created on 01 05 2014 Page 18 Introduction TSM Batch Blender Standard Blender configuration for Customer Throughput Requirements When the TSM Sigmabatch blender leaves the factory it is set to a standard configuration unless specified otherwise by the customer The tables below
18. 4 Page 2 Quick Start 5 Entering Set points Touch pA Touch Ai Enter the operator password default set to 1 Recipe entry modes Auto The recipe entry mode will be factory set so that component 1 does not need to be entered The required quantity of natural material is calculated by the blender Manual If preferred the recipe entry mode can be set to manual All of the component T percentages need to be entered and it is necessary for the operator to verify that BN they total 100 If they don t total 100 the recipe cannot be started and a warning icon is displayed NOTE Once a recipe is successfully entered it is automatically stored in the recipe memory and allocated a number displayed in the recipe book recipe name and the recipe number are also stored Up to 100 lt recipes can be stored Use the to move between recipes Entering recipe name alphanumeric Touch this icon and enter the recipe name Up to 10 characters aA To enter the setpoint percentages for the individial components touch the corosponding percentage as shown and the numeriaal keypad will appear Remember component 1 is automaticly calculated Enter the percentage and then touch 9 Created on 01 05 2014 Page 3 TSM Quick Start Regrind optional If a regrind is added to the recipe there are 2 options Regrind can be treated as part of the 100 calculation R 100 or it can add
19. 50 39000 ___ 1 Compi Comp Comp1 Compi 2 2 Comp2 Comp2 Comp2 S39 Comp3 Comp3 Comp3 4 4 Comp4 Comp4 Comp4 5 WH WH WH WH 9 6 GND GND GND GND 7 5 Comp5 7 Comp5 8 Comp6 Comp6 Comp6 9 NA 1 Comp5 10 NA NA 7 Comp6 Comp8 1 DMP DMP DMP DM 12 GND GND GND GND HEV A7 Created on 01 05 2014 Micro dose feeder optional WH weight hopper C Cleaning DMP Air Dump Maintenance TSM EUROPEAN 3 PHASE WiRING CONNECTIONS excluding Optimix 50 150 250 5 phose box dim gt lf 72 72 lt M Single Phose to NBB 2 gt lt MIXING 3580 410V 2 50 60 HZ 452 1 Hats Netre resent In 3 phase suppy 2 jS pause vollege maserar 410MM FILE 3 Phase Box ABB Al dwg 13 12 2011 REV A7 Created 01 05 2014 Page 27 Maintenance TSM USA 3 PHASE WIRING CONNECTIONS excluding Optimix 50 150 250 3 phose box BLK BLK BLK m m Ay x 22 gu om m r A yz E ONT ACTOR Y NV V 23 ee gt 5 zi Ll el uv el s 2 2 gd lt 0 i Single Phose anu NBB SUPPLY 2 o gt lt MIXING 580 460 E M
20. 9 O OQ l3NIBHvO 300 MLIX3 NI QO3LSIALL O HiNv3 NvV31O OL PN LS 5 193NNOO D 0 z 2 x z NOlLISOd WSL NI NMOHS HOLIMS gt HOUMS 3AO 39NvHO 310d Z 2 2 9 4 URES ANAE Rive 42901510 C LNNOO O A0L 0 z 7 www 2 Jolo 2 ONU an iunt ez 30N3 3438 m LL 01912 2 9 TEHAL WINVR OLN ca Z Ol 135 51 LMS 38nSN3 zi d3llld SI Z1 33nsN3 K lt LMS 41 mU WANWA OLNY TT i OM3Z OL SI 5 1ndino A01 0 TUNN LLOWSY B LNVIS SIN3A33d 3SV3HONI rT 8NNOO ZNNOO ONNO2 O HOLIMS l1NVIS 30 1 3SV3H030 r E DEXXEXEX 531035 NI SHIM O XI o Lilli LL v w z cig 112 E38 a EIER 4 5 212 Sle EIS ed 4 o zm S _ G l gt 5 2 2 5 lt SE ELENI TONS 7764 11045 eU 13326 INN i 01 05 2014 Page 9 Extrusion Control Rev7 TSM Extruder Start Switch mm mm om me R WIRING THE EXTRUDER START SWITCH IN SERIES WITH THE START UP RELAY ENDE ITHE SEI START UP RELAY IS START aus DESIGNED TO CLOSE WHEN THE SWITCH L R av SPEED SETPOINT IS LESS THAN 5 x THE EXTRUDER START SWITCH MUST
21. A Power Consumption 0 15KW Specification Note Batch Blender Specifications TSM SigmaBatch Blender OPTIMIX50 150 view Maximum throughput rates are based on using all dispense valves using standard material Use of feeders will reduce this rate REV A6 Created on 01 05 2014 Page 11 Introduction TS M Batch Blender Blender Component Configuration 22 Specifications TSM SigmaBatch Blender Optimix 3000 Optimix 1000 Optimix 650 Optimix 350 8 Slide Gates up to 4 side feeders 4 Slide Gates up to 4 side feeders 4 Slide Gates up to 4 side feeders 4 Slide Gates up to 2 side feeders 4 Slide Gates No side feeders x x x 1000 kg x 1600 kg x 3000 kg x 660 Ibs 1430 Ibs 2200 Ibs 3530 Ibs 6610 Ibs x 2 kg x 4 kg x 7 kg x 12 kg x 25 kg x 4 4lbs 95 1 1 6 506 71 54 MexCompnns 4 6 8 8 9 BishageVavs 4 424 14 14 8 Jy 0 2 4 4 4 REV A6 Created on 01 05 2014 Page 12 Introduction Batch Blender Teevughput Hopi Bin Capacity Exch Lira E Bundes Width mme F kepp fiin Frant Widtis mm f upper fun Fiant Wit mm Q fete en oan wine eel 130v 248 18 sso _ _ 20124030 ADR May 410 33 39 Harmur rates ars o mH itd hejar ncm anlan The Creede rada Bale Sa ot
22. A7 Created on 01 05 2014 Page 6 Maintenance When a problem affecting one of the material components occurs TSM ALARM flashes beside the component number on the Production Summary screen The blender continues to operate in automatic mode Alarm Summary screen displays an alarm message Alarm message Fill Problem on Blend x The blender was unable to fill the weigh hopper to the target weight from the component number displayed in the message REV A7 Created on 01 05 2014 Possible cause Is there material in the hopper above the slide gate Does the recipe call for more material than the component valve or feeder can deliver Refer to the percentage chart page 20 in the introduction section Has material bridged over the bin discharge blocking material flow valve for this component fail to open errem ss Did the side feeder fail to operate Batch Blender Component Alarms Solution Ejluuuppupuu p r Verify that there is material in the bin or feed hopper and that the loading system supplies sufficient material The material may have arrived after the alarm occurred Verify that the side feeder or material slide valve opening is the correct size for this application Trying to put too much material through a feed valve that has a flow reducer insert can cause this alarm d Verify that material is free to flow into
23. EV 9 Created on 01 05 2014 Page 1 TSM Quick Start 3 Tare the Hopper setting the zero point Ensure that the mixing chamber door is open and there is nothing touching the weight hopper before attempting to tare the load cell With the weigh hopper empty allow the weight 1 gt K reading to stabilize and then touch This value now becomes the zero reference point for the load cell readings 4 Check Weight Calibration Gently slide the weigh hopper out and place a known weight into it use a weight close to the batch size Touch this icon and if for example if the calibration weight is 1kg enter 1 on the numeric keypad The lower value on this icon is the actual weight e he Blender automatically re calibrates itself and the actual weight should now be displayed correctly e Remove weight from hopper Weight Kg should now return to zero Blender Recommended Load cell Type Batch size Max weight The ideal batch weight will be factory set oe a 559 If it is necessary the batch weight can be _TSM350 2Kg 45lb 10 0 changed inside the engineering section TSM650 3Kg 6 5lb 10 Kg TSM1000 5Koiib 20Kg TSM1600 7Kg i5blb 20Kg TSM3000 25Kg 50b 40Kg Upon sucessful completion procede to enter the first recipe name and setpoints e Use to exit to calibration Menu amp save settings or Fl to go to the home screen HEV 9 Created on 01 05 201
24. Extrusion Control Rev7 EXTRUDER DRIVE A PUSH TO START SWITCH IF IT IS NOT THEN THE EXTRUDER WILL STOP WHEN 5 SPEED EXCEEDS coe THIS FUNCTION PROTECTS THE XTRUDER FROM BEING STARTED WHEN THE SPEED SETPOINT IS TOO NER RR USM Systems 01 05 2014 TSM Change over Switch for backup only 1 FIRST ANGLE PROJECTION EA am I r Mn CONN 12 LJ d CI gu Ca l 2 POSITION 73 T PS zi CHANG F OVER NO VN No O V 10V SETPOINT REF EXTRUDER DRIVE fer CHANGE OVER SWITCH Tg Contral Systems Extrusion Control Rev7 01 05 2014 Page 11 CO EA EXTRUSION CONTROL CONNECTIONS EXAMPLE SHOWN FOR 5 LAYER CO EX LINE LINE SPEED SIGNAL CONNECTED EACH SEI MODULE ONLY CONNECT 24vDC FROM ONE SEI CARD AS SHOWN 4 dl PETS eren eo a ie EXTRUDER EXTRUDER EXTRUDER C Extrusion Control Rev7 01 05 2014 Page 12 TSM SEI Mounting the line speed encoder There are 2 main haul off types 1 Horizontal oscillating haul off This is the most common type When this type is used we recommend that the line speed encoder be mounted on a film driven roller so it measures the actual speed of the film close to the winder The reason for this is that it is possible that the film can shrink or stretch a
25. I network connection HEV A6 Created on 01 05 2014 Batch Blender oystem menu Page 11 User manual TSM Batch Blender SES Load Cell Calibration Explained see the quick start guide for how to calibrate the load cell This option is used to ensure accurate weighing of material As the procedure for calibrating the hopper is already dealt with in the Quick Start Guide this section will only define the options contained ME Tare zero 1 9 The blender front door must lt J be open to tare the hopper Hopper Weight icon Displays the current weight inthe weigh hopper When the weight hopper the calibration weight can be entered here BW Fill Target WT kg The batch weight can be seen here but cannot be changed change this it is necessary to use the engineer menu icon The two values shown on the bottom right of the screen are e CC This value is the Calibration constant The blender uses this constant to calculate the weight from the load cell A D counts e A D Counts Analog to Digital readouts from the load cell e A D Tare Counts Zero reference point after the hopper has been tared These values are useful when diagnosing the load cell HEV A6 Created on 01 05 2014 Page 12 User manual TSM Batch Blender Diagnostics To access the diagnostics page from the System menu touch This menu allows you to Check the comms diagnostics
26. OTOR 50 60 HZ 4321 Rete Adcitianel switch centack X Y if present 3 phcse supply eed exla Sngle phase s pply 2 3 p usgB 4 veed exlra single phase s pply HEV A7 Created on 01 05 2014 Page 28 Maintenance NBB OVERVIEW IEE YUPI E i SE GT ao H T BE is ea wwe cma EN M REM SEE LDA amp OCE L maiihi ag TOR wEAS HEMET LT CONN B amp LX er Load Phone 233342 8034340 1208 34v 318 oe CONNS HIGH enn Lascia n he uve m n aw SENVOM r GRD w o 2 wer 3 YEL HIGH a Ri ue Au mg DET 5 WIEN Posies isis 3 Wee Esau 1 7 en F WHT SSM Bh HEV A7 Created 01 05 2014 Page 29 TSM NBB PSU Module Maintenance NBB PSU MODULE CONNIE MOLEX Page 30 REV A7 Created on 01 05 2014 Maintenance m 1 1 al gt EIME SUB WEIGH HOPPER HANGER 2 LHS 136 HANGER 2 RHS 1366 EASY DRAIN TOP DOOR INTERLOCK LOAD CELL BRACKET 2 VENTURI SIDE FEEDER DRAIN SLIDE ASSEMBLY BIN ASSEMBLY U 3087 REV A7 Created on 01 05 2014 Maintenance
27. SE Common Start up Issues Extrusion Control SEI is not working Check that it is wired correctly See previous page for the SEI overview and the Maintenance section for the wiring diagrams Ensure that 24 volts are present on the SEI Verify that the 24V LED is on and the Run LED is flashing see SEI overlay diagram previous page The LED will flash at a regular rate if the card is functional Check that the Tx Rx LED is flashing If not check that the communications cable to the blender has been wired correctly Is the SEI card enabled in the configuration section of the blender page 2 mI c Ye line speed is not Ensure that the line speed wheel is wired working correctly Check that there is 24V between red and blue wires If you are using a TSM line speed wheel ensure that the lines peed constant is set to 2000 in the Line and screw speed calibration menu screen Shown in main user manual Make sure that the line speed wheel is in contact with a film driven roller and is able to rotate freely Ensure the line speed cable is not running close to high voltage power lines Extrusion Control Rev7 01 05 2014 Page 15 SEI TSM EXTRUSION RELATED ALARMS Check that the shield ET may be necessary to reroute the SEI 0 on the comms cable is comms cable to move it away from connected and that the high voltage cables SEI Reset cable is If you are getting more than 10 e
28. TSM Sigmabatch Batch e nd er Installation Manual Version 5 User Manual Instant Access Parts and Service 35342 9335560 35342 9334422 www tsmcontrols com info tsm controls com DISCLAIMER TSM Control Systems Ltd shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information TSM makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 1999 All rights reserved TSM Control Systems Ltd Please record your equipment s model and serial number s and the date you received it in the spaces provided Introduction Purpose of the manual Warnings How to use the lockout device Description How it works Blender Overview Features and options Specifications TSM Sigmabatch blender Blender component configuration Blender adapters Blender element check list Mounting equipment Connecting power Connecting air Configuring Blender for customer throughput requirements General wiring considerations Quick Start Initial setup Calibration Tareing the hopper Check weight calibration Entering set points Alarm description Common start up issues Extrusion control SEI functionality Connection of SEI Checking operation Diagnostics Checking SEI outputs Entering extrusion
29. Wheel Route the line speed wheel cable back to Conn 7 of the SEI Ensure correct polarity of connection and avoid running cables close to power lines Connect Line speed signal from the Line speed encoder and roll changes contacts if required to CONN 7 and CONN 8 respectively WARNING if connecting the line speed encoder to more than one SEI card only supply the 24v from one SEI card Extrusion Control Rev7 01 05 2014 Page 2 SEI Checking Operation of the SEI e Check that the wiring from the NBB electronics module to the SEI is correct e Ensure that the SEI powers up when the blender is switched on the LED s on the SEI card will flash at regular intervals e Check that the SEI is enabled in the blender software 1 On the Production Summary screen touch the Icon 2 Enter the password factory default 5560 Touch the TSM icon and enter the Password Factory default 9335 5 o move onto next page touch 6 Check that Remote Modules option is set to SEI 7 f it is not selected touch the disable option to scroll to the SEI option 8 Exit the page using the back option to save Extrusion Control Rev7 01 05 2014 Page 3 SEI Diagnostics Check the Diagnostics page to see if the SEI is working correctly e From the Production Summary page touch e When prompted enter in the Password e Once in the System menu touch and k Good Transmit Tx This indic
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31. amiliar with the construction operation and potential hazards of this type of equipment All wiring disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical standards and codes in your region Always maintain a safe earth connection Do not operate the equipment at power levels other than what is specified on the equipment serial number tag and data plate WARNING Electrical shock hazard This equipment is powered by single phase and or three phase mains voltage as specified on the machine serial tag and data plate A properly sized conductive earth wire from the incoming power supply must be connected to the chassis earth terminal Improper earthing can result in personal injury and erratic machine operation Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non standard operating procedures such as troubleshooting or routine maintenance WARNING Do not remove or disable safety devices Electrical interlocks are installed on the mixing chamber and material bin doors to prevent blender operation when the doors are opened if the bins have not fitted with finger guards REV A6 Created on 01 05 2014 Page 3 Introduction TS Batch Blender WARNING Pinch hazard This equipment is equippe
32. ates the number of messages that are transmitted vi WE e hen touch Power up 00 ss 00 00 Malo eS Good Receive Rx This indicates the number of messages received Checksum Error C Sum This indicates that the selected unit received the response but the checksum was incorrect when the complete message was received I E the message could not be understood Timeout This indicates the number of times that the unit was transmitted to without a response The counters are displayed for the Remote Display low level sensor card Network and the SEI Ideally the TX and the RX counts should be the same if you have more than 10 csum errors or timeouts then the communications are not working correctly Reset the counters using the reset icon and allow them to count up to 100 counts as the errors may have accumulated over time If the SEI is not communicating Double check the wiring and then contact TSM for further assistance Extrusion Control Rev7 01 05 2014 Page 4 SEI To check that SEI is providing the correct voltage 0 10V on CONN 12 e Fora screw speed setpoint voltage to Extruder Drive of 1096 use a voltmeter to check that 1 0 volt is present between pins 1 and 2 of Conn12 of the SEI card 0 0 00 Example If the screw speed setpoint is i y the voltage should be 2 54 Volts nu 0 009 0 0097 0 0 check that Lines peed an
33. closed Check that the system is not in PAUSE mode Check status of the appropriate LED indicator on the NBB The LED should be on when motor is active Please check quick start guide FAQ section Please check quick start guide FAQ section All of the blender information can be displayed by touching the 9 icon on the top right of the home screen see page 3 of the user manual for a more detailed description Sometimes a faulty load cell may affect accuracy refer to page 2 in the Quick Start Guide to check the weight measurement Running the blender automatic test routine identify the source of the blender inaccuracies TSM blenders incorporate and advanced vibration filtering system however lf there is excessive vibration on the blender and it is affecting accuracy the blender may need to be isolated from the extruder HEV A7 Created on 01 05 2014 Frequently Asked Questions Page 19 Maintenance TSM Extrusion Control problems How can Extrusion Control works by monitoring the Extrusion throughput of material and adjusting either the Control extruder or haul off soeed to keep it constant This means that either the throughput or the process weight per length and thus the gauge of the extruded product can be kept constant This leads to improved quality reduced start up time and reduced material usage because it allows the process to run at minimum tolerances My extruder
34. costa F bulk Genet Thru aed een operate cn using matecigu Avr regnis muss sab T ehh bo Ure mache beei REV A6 Created on 01 05 2014 Introduction Adaptor Options 150 d T3 i This neck is used for the following applications Options Manual Flow Control valve Pneumatic Flow Control valve Material Level Sensor Material Drain Chute Notes Fits directly under TSM Blender Blanking Plate available if no Flow Control valve required Suitable blenders and adaptors are listed on previous page Suitable for 50mm outlet only HEV A6 Created on 01 05 2014 x y fiere cu 4 This neck is used in applications where the TSM Material By Pass system and Automatic Cleaning is required Options Pneumatic Flow Control valve Material By Pass Material Level Sensor Material Drain Chute Notes Fits directly under TSM Blender No Blanking Plate required Suitable adaptors and Blenders are listed on previous page Suitable for 50mm outlet only Batch Blender 200 This neck is used for the following applications Options Manual Flow Control valve Pneumatic Flow Control valve Material Level Sensor Material Drain Chute Notes Fits directly under TSM Blender Blanking Plate available if no Flow Control valve required
35. cover Locate the dip switches and set them as shown below switches Dip Switch Settings s m d d lot af 31 In this mode when you power on the Touch panel the screen will display a sign at the center of the screen Use a stylus or finger to push the center of the until It moves The moves to upper left upper right lower left lower right and center When all five 5 done the will disappear The Touch Screen parameter is automatically stored Power off the panel and put the dip switches back as shown below HEV A7 Created on 01 05 2014 Page 14 Maintenance TSM Wiring Considerations Blender is not powering up correctly Communications errors Visible on diagnostics screen Do NOT run TSM cables with high voltage cables Why is it necessary to keep communications cables and material conveying lines separate Please check quick start guide FAQ section If communications to devices are showing more than 10 timeouts TSM diagnostic displays check that the communication cables are not routed along side high voltage cables Ensure that cable shields are terminated properly The wires connecting the various elements of a TSM system are normally communications data lines and are low voltage As such care should be taken to keep them well removed from high voltage lines DO NOT RUN HIGH AND LOW
36. d default 5560 C Touch the TSM icon and enter the Password Factory default 9335 D Touch o open the config 6 Menu 272923 loq this r F If the correct mode of operation is already selected touch Back If it is not Touch the option until the g m option is displayed Touch Back to exit and save your settings Extrusion Control Rev7 01 05 2014 Page 7 Starting the Extruder SEI Before starting the extruder ensure that the Control Output is set to 0 096 To get to the extrusion control screen touch ed If the set point is not set to 096 touch the arrow on the screen Starting the Extruder Drive Increase the screw speed gradually by touching the on the touch screen until the actual g m is almost the same as the g m set point 4 3 5 g m Allow the blender to complete 4 cycles This is only necessary if the blender has not cycled since it was powered up Check that the actual weight per length is registering the production summary screen and it is within 3 5g m Now switch the blender to Auto by touching on the operator panel The extruder speed now wil be controlled automatically to set maintain the w m or kg h set point The red man icon will change to Auto and turn green Extrusion Control Rev7 0 00 01 05 2014 Page 8 Serial Extruder Interface SEI Overlay Diagram YyL 60 66 wt KES 318v
37. d Increase Decrease optional are operating correctly Rotate line speed wheel and check that line speed is changing on the Production Summary page m min This indicates that the line speed is being received If remote increase decrease switches are connected to SEI card check that this operates in the same way as the Increase Decrease keys on the Remote Operator Panel Extrusion Control Rev7 01 05 2014 Page 5 SEI To enter weight length set point On the Production Summary screen touch 7 i e Enter the operator password default 1 e Enter the component percentages as per the instructions in the quick start section us Touch the extruder tab and enter in the appropriate Weight Length set point Calculating Weight Length Set points Extrusion Control Mode Only In weight per length mode the user may enter the set point grams or lbs per meter or per foot calculate the g m g m z thickness microns x 2 x width Meters x density e density average density of all components e Ensure that the blender is in the appropriate extrusion control mode by following these steps Extrusion Control Rev7 01 05 2014 Page 6 SEI Configuring Blender for G m Extrusion Control this is a licensed option and will need a license code form TSM to be activated If the blender is not configured to operate in G M mode E LG E si A On the Production Summary screen touch B Enter passwor
38. d with pneumatic slide gates which are mounted on the blender frame beneath the material bins Always disconnect and lock out the incoming compressed air and electrical power supplies before working near these slide gates Failure to do so could result in serious injury The material bins are equipped with finger guards These should never be removed unless adequate precautions are taken to secure the Perspex door on the bin It is recommended a safety interlock is fitted to the door or at least that the thumb screw is removed and replaced with a security bolt to prevent any unauthorized person opening the door WARNING Rotating auger hazard The mixing chamber and additive feeders on some TSM blenders contain rotating augers Always stop the blender and disconnect the main power supply before opening the mixing chamber or opening the feeder drain door Rotating augers can cause serious injury CAUTION Flying objects TSM blenders are equipped with a compressed air gun that can be used for cleaning the bins and mix chamber To avoid potential injury you must observe all safety regulations that apply to the use of compressed air for cleaning equipment Adjust air pressure to no more than 7 5 Bar 110 PSI Wear protective goggles and clothing to prevent injury from flying particles and objects TSM has made every effort to prevent injury to prevent injury by installing the following safety devices Door interlock The ACCESS DOOR is equipp
39. de This mode will be displayed on the top right corner of the home screen 1 Touching the icon and then the icon will take you to the blender information page On this page it is possible to see if the software is trying to open the slide valve lf the software is switching on the output but the slide valve is not opening then the next place to check is on the control module 2 On the control module card there are LED s for each output These are located directly above Conn 2 valve connections See page 25 for layout and led description 3 On the Festo valve block there are LED s for each valve If the LED on the control module is activating and the led on the valve block is not then check the connections between the control module and the valve block 4 There is a blue manual activation switch on the valve block pushing it up should activate the valve remember there may be material in the hopper so be careful opening activating the valve for long periods 5 Check there are no bends or kinks in air lines running between the valve block and the slide gate Micradose valve 6 Empty the material hopper Open the front door of the blender and remove the hopper Manually move the slide valve to ensure it can move freely HEV A7 Created on 01 05 2014 Page 12 Maintenance TSM Checking side Feeders DANGER Electrical shock hazard Always disconnect and lock out the main power supply before opening the blender electrica
40. der has not cycled for X minutes this option will stop the extruder Haul off SEI is not communicating Check the connections to the SEI and ensure that the card address is set to 1 Haul off control alarm has been generated because the haul off could not be controlled within the haul off control band Line communications alarm indicates that one or more of the controllers has stopped communicating The CP9000 has stopped communicating with the blender check connections to the CP9000 Haul off speed setpoint was not achieved when the system attempted to set the haul off speed The feedback from the extruder indicated that the 322 None system could not set the extruder to the required speed REV 9 Created on 01 05 2014 Page 7 TSM Quick Start Vacuum System Alarms Vacuum Receiver alarm The receiver number X failed to fill check vacuum recevier Software License timeout The software license timed out please contact TSM Calibration Alarm The calibration data was restored from memory software security alarm The NBB will need to be returned to TSM SD card Alarm System cannot write to the SD card The SD card needs to be re formatted or replaced Invalid config If there is a problem with the calibration data on power up Problem with the board memory 3 1 1 None Po fl Ethernetalarm C 314 None Reset the blender o
41. each material one at a time The blender will start by filling the largest component first When the level sensor in the mixing chamber becomes uncovered the batch will drop and the cycle will start again HEV A6 Created on 01 05 2014 Page 7 Operator Touch panel ho 1 Removable Hoppers NN 4 The Opti mix has been designed with its dispensing valve incorporated into the hopper To remove the hopper the operator simply releases the two air supply quick release connections Emptying and cleaning the hopper can be completed in less than a minute due to the unique design TSM UPFTI MIX HEV A6 Created on 01 05 2014 Up to Eight main Material Bins depending on Model Located above the blender frame and slide valves these bins contain the material to be deposited into the weigh hopper for blending Viewing Windows Clear visibility of material levels in the bins Pneumatic slide valves slide valve is located inside each material for dispensing material into the weigh hopper The openings can be different sizes depending on the percentages required Load Cell above weigh hopper The load converts the mechanical force of the material load into an electrical signal Since the load cell is a delicate transducer it should be treated carefully should not be subjected to severe mechanical shocks Mix Chamber Access Door The l
42. ed outside the 100 calculation R 96 100 Factory default To add a regrind component touch the blue tab Touching the recycle icon allows you to select the regrind hopper To start a valid recipe that vou have just entered e After confirming the recipe Z number ER When you RUN the recipe you have two options 1 You can reset the order totals 2 gt 0 reset the order report totals 2 You can start the cleaning cycle optional amp The options are enabled disabled by touching REV 9 Created on 01 05 2014 Page 4 TSM Quick Start Blender Alarms Component fill alarm The required amount of material did not fall through the slide gate The component number will also be displayed Mixing Screw The mixing screw output had tripped out due to over Current In offline mode the blender can be set to dispense a certain amount of material and this alarm is displayed when the blender is complete Component Percentages are not adding up to 100 Deviation alarm The actual percentage of x component is not correct The material in the mixer has fallen below the Level sensor alarm 176 Mn level sensor before the next batch was ready 2 Hopper Leak alarm 192 S She The weight hopper flap failed to close completely m Low Level alarm optional 208 The material has fallen below the sensor in the reservoir hopper 224 During the cycle the
43. ed with a safety interlock switch that prevents the mix motor from running and the slide valves from operating DO NOT defeat this safety switch HOPPER FINGER GUARDS Finger guards are fitted into each hopper compartment DO NOT reach through these guards DO NOT use your fingers to clear an obstruction below these guards DO NOT remove these guards If itis necessary to remove the finger guards then it is necessary to install interlock switches on easily opened windows If this is not possible then the thumb screw should be replaced with a security bolt to prevent any unauthorized access Motor finger guard A finger guard has been fitted around the motor shaft to prevent injury Electrical enclosures have been secured so that it is necessary to use a tool to open them REV A6 Created on 01 05 2014 Page 4 Introduction TS M Batch Blender How to Use the Lockout Device Only qualified electrical personnel should attempt to carry out electrical maintenance on this product Before performing maintenance or repairs on this product you should disconnect and lock out electrical power sources to prevent injury from unexpected energisation or start up Lockout is the preferred method of isolating machines or equipment from energy sources Depending on the blender mode TSM three phase blenders have been equipped with the lockout device pictured below To use the lockout device on Optimix 350 650 1000 1500 3000 e Stop and switch the e
44. ere are any timeouts then the test is deemed to have failed 17 Comm LLS Communication is checked over a 2 second period if there are any timeouts then the test is deemed to have failed 18 Comm Op Communication is checked over a 2 second period if there are any timeouts then the test is deemed to have failed 19 Comm Net Communication is checked over a 2 second period if there are any timeouts then the test is deemed to have failed 20 Comm TCP IP Communication is checked over a 2 second period if there are any timeouts then the test is deemed to have failed HEV A6 Created on 01 05 2014 Page 16 User manual Batch Blender Settings 05 2010 10 73 00 Use this option to set the correct time day 3 10 23 00 and date Touch the appropriate box on the J Line and enter the new value Touch the save icon to update the Passwords This screen can be used to change the operator and supervisor passwords 3 Operator password This allows the operator access into the recipe section 5 3j 3 supervisor password This allows the supervisor into the recipe section and also the system settings This password should be restricted to authorised personnel as it allows access to the blander calibration settings oee the quick start section of this manual for the factory set passwords NOTE It is important to make a note of the new passwords HEV A6 Created on 01 05 2014 Page 17 User
45. erial Check the level of material in the mixing chamber If material is covering the level sensor even though it failed to detect material verity that the level sensor wire is securely connected to the correct terminal in the blender wiring cabinet verify that the level sensor sensitivity setting is correct There is an adjustment pot on the sensor g Using this icon on the Reports blender information screen you can check if the blender is reading the sensor correctly Page 8 Maintenance TSM Batch Blender m Alarm Continued oyste arms Alarm message Possible cause Solution Has new version of the Verify and re enter calibration control software been information as needed or installed recently the calibration data can be reloaded from the SD card If the problem persists contact TSM service technicians Calibration Data Alarm The calibration data stored in the blender has become corrupted i Something has stopped current trip needs to be 2 the mixing screw reset after checking that there is y Y w causing the current trip nothing stopping the mixing to trip screw from turning It may be Mixing Screw necessary to remove the screw 52 2 22 The recipe has been Recheck the recipe 0 100 entered wrong This alarm should not occur if you are using the auto recipe Component entry setting Percentages are not adding u
46. he load cell cannot move from side to side on the mounting block Also verify that the bolts securing the weigh hopper mounting bracket to the load cell are tight e f the slide valves have been fitted with guards check that there is adequate space between the guards and the load cell bracket e Replace the weigh hopper on the load cell e Calibrate the Hopper See the quick start guide for information on how to do this e fthe weight reading is not stable or you have to carry out the calibration more than once a month contact TSM Support Services for further instructions REV A7 Created on 01 05 2014 Page 11 Maintenance TSM Checking Fill Valves DANGER Electrical shock hazard Always disconnect and lock out the main power supply before opening the blender electrical enclosure The solenoid valves are connected to the main voltage supply Procedures that require access to the electrical enclosure while power is on should be performed only by qualified electrical technicians who know how to use electrical testing equipment and understand the hazards involved There is one air operated slide valve or Micradose valve associated with each compartment of the material bin Solenoids located on the back of the blender control the slide valves Solenoid source drivers located on the control module control the solenoid for each valve Diagnose the problem by following the steps below 1 Ensure the blender is not in stop pause mo
47. ide valve size configurations If a lower is required for any component the appropriate insert must be attached oee blender introduction section page 20 for standard slide valve size configurations When using the See the Micradose feeder 96 range specification MICRADOSE tables in the SigmaBatch Quick Start guide for FEEDERS my the minimum and maximum 96 of batch weight blender does not which can be fed for each component seem to be achieving the required accuracy Operator Panel The Operator Please Check Quick Start Guide FAQ Section Panel is not e Page working what should do Other hardware If the mixing On the 3 phase models be sure that the current trip motor is not has not blown It can be reset by pushing the reset rotating button on the current trip located in the blender contactor box Please check quick start guide FAQ section PAGE 7 HEV A7 Created on 01 05 2014 Page 17 Maintenance The mixing motor does not seem to be rotating in the correct direction what should do 3 phase models only If the Dump Flap olide Gates are not operating The mixing auger should rotate in a clockwise direction when looking at the shaft of the motor from the motor end conveying material to the center of the chamber If the direction of the mixing auger is incorrect Switch mains power switch to off and lock it out Disconnect mains power supply externally to blender
48. l enclosure The solenoid valves are connected to the main voltage supply Procedures that require access to the electrical enclosure while power is on should be performed only by qualified electrical technicians who know how to use electrical testing equipment and understand the hazards involved To check the feeders e Ensure the blender is not stop pause mode This mode will be displayed on the top right corner of the home screen e Ensure the outlet from the material hopper is not obstructed e For the Micradose feeders check that quick release air pipe is connected e Use the same procedure outlined on the previous page to check the side feeders e Check that the light on the solenoid turns on as each feeder is activated If the valve does not turn ensure that the connector is securely fitted See page 25 for the LED identification If the connection is good check the 24v is being outputted from the control module e There is a manual activation button on the valve push this to check that the valve operates manually If there is still a problem contact TSM Support Services REV A7 Created on 01 05 2014 Page 13 Maintenance TSM Calibrating the operator touch panel The touch panel should not need to be regularly calibrated but if there is a problem then it can be calibrated as follows To get the touch panel into Calibrate mode Rear View Power off the touch panel and remove the back I
49. lean the filter bowl If necessary B Inspect the mix auger Verify that the mix auger turns easily within the chamber If the auger makes noise when rotating or does not turn easily you may need to lubricate the ends of the auger with a commercial lubricant c If the mix auger flights become sharp or damaged through wear replace it Monthly A Inspect power cables wires and electrical connections B Check for loose or exposed wires burned contacts and signs of damaged wires C Check exterior power cords to the main power source D Inspect air connections hoses lines for wear or damage E Tighten connections or replace damaged parts The load cell calibration should be checked at least 3 4 times per year Failure to do this could result in production errors or losses Please refer to the quick start section of this manual for how to calibrate the load cell REV A7 Created on 01 05 2014 Page 1 Maintenance TSM Batch Blender 3 WARNING Pinch and auger hazards This equipment is equipped with pneumatic slide gates beneath the material bins and may have a pneumatic slide gate beneath the rotating augers in the side feeders and mixing chamber Always disconnect and lock out the incoming power source before cleaning the blender or feeder Always disconnect the compressed air source before working near the slide gates Failure to do so could result in serious injury Blender Cleaning All TSM blenders include an access do
50. me lifting hooks on smaller blenders 2 Position secure and bolt the blender onto the processing machine or stand Allow easy access to the mixing chamber door for cleaning purposes It is the responsibility of the user to ensure that the blender is supported laterally as required to avoid excessive deflection on the neck during operation 3 Change the bin lifting hooks into the correct position for lifting as shown above Mount reservoir bin on top of blender frame as in Fig 1 1 5 f applicable mount material loading equipment on top of reservoir bin gt 6 Gently position the weigh hopper onto the bracket in the mixing chamber taking care not to damage the weigh mechanism loadcell 6 Connect the air pipe to the weigh hopper piston Push fit 7 Mount the operator touch panel Fig 1 3 in an appropriate location for the user 8 Connect remote operator panel to D type connector that is connected to the SBB200 1 electronics module in the blender control cabinet Note Please ensure that the acrylic door of the blender is kept closed during its unpacking and mounting This will help prevent damage to the delicate weigh mechanism load cell The Remote Operator Touch panel requires careful handling REV A6 Created on 01 05 2014 Page 16 Introduction Batch Blender Connecting Power The 3 phase power should be connected to the terminals as shown below European USA Power Earth 0 2 1 110V1 6
51. n the card to the NBB console Software update instructions 5 3 Page Software Update TS M 7 On the touch screen touch factory set to 5560 and enter the password Then I and open the screen shown in FIG To start the update touch 2 2 b Qm auupcdcoate zias9 L aioe E I mt O4 UE S lap ER diii PER or oress software update ari RT The screen will go blank for about a minute see Fig 4 Software update instructions 5 3 Page 2 Software Update TS M Press a icon and check that the software version has been updated TIN C P 2 4 0 Kg 1 332C FF SB 02 00 00 53 010 000 000 175 000 000 000 000 00 03 F4 04 50 63 5 Software update instructions 5 3 Page 3 TS M Batch Blender To remove the sd card from the blender do the following To do this I Touch the 1 Warning The SD card must be disabled before being removed FIG 1 2 The information screen will open FIG 2 This icon will be shown if the SD card 15 in position Fr azten t Mers lon Fi 3 17 E Pul hp THY 3 Touching Li allows the SD card to be safely Pia E ALME 3 1 E removed When the icon turns red 3 The Hi ee Le eer SD card is safe to remove The safe mode Eur 1 eee will time
52. n the load cell bracket Close the mixing chamber and material bin doors REV A7 Created on 01 05 2014 Page 3 Maintenance TSM Batch Blender Troubleshooting Foreword Page 5 Word of Caution Page 5 Identifying the Cause of a Problem Page 6 Component Alarms Page 7 oystem Alarms Page 8 Checking the Load Cell Page 11 Checking and Replacing slide gates Page 12 Checking and Replacing Feeders Page 13 Frequently Asked Questions Page 14 REV A7 Created on 01 05 2014 Page 4 Maintenance TS M Forward Before you begin troubleshooting 1 Refer to the wiring diagrams and other schematics that were shipped with your equipment The diagrams should note any custom features such as special wiring or control options not covered in this User Guide Verify that you have all instructional materials related to the TSM SigmaBatch blender its control systems and its components Additional details about troubleshooting and repairing specific components are in these manuals Verify that you have manuals for equipment located upstream and downstream from the blender Solving problems related to material conveyed to the blender or to extrusion quality may require troubleshooting equipment in the extrusion line Word of Caution WARNING This machine should be adjusted and serviced only by qualified technical personnel who are familiar with the construction and operation of this type of equipment DANGER Voltage
53. na 5 ae lice there is a problem with the blender TSM may ask for one of these options to be enabled pm This option can be used to log the Alarms FUN Alarms and Batch Logging When either if these options are enabled the blender will then start logging its Alarms batch information to the SD card or USB drive This information can be emailed to TSM to help diagnose a problem The batch logging should be turned off when not in use to lengthen the life of the SD card HEV A6 Created on 01 05 2014 Page 14 User manual TSM Batch Blender Telnet This remote diagnostic option allows TSM to remotely connect to the blender if the blender has a working network connection Touch to enable REV A6 Created on 01 05 2014 Page 15 User manual TSM Batch Blender Blender Self Test This option allows the blender to run a self diagnostic check efTet _ gt Always running 1 Loadcell 111 Events Ad test runs automatically and there should 2 A D 12 Tare Alarm Z geopper Tare B Leak nm kh Comp Tare H4 Dump bea to show that the Load cell passed its 5 Tare Dev 15 Comm Panel stability test 6 Cal Const 1 Comm SEI 2 Comp Retry comm LES B Std Dev s Comm Opt 19 Comm Met aJ Comm 21 Manually running the Self Test WARNING The Self Test will pause the blender for 25 30 seconds and therefore should only be used when the line is
54. ne in four easy steps 1 Switch all power off the blender 2 Open the tray on the bottom of the NBB console and disconnect all of the cables 3 Open the thumb screw on top of the console 4 Lift off the console Then remove the SD card from the SD card slot see previous page for location and insert it into the new board HEV A7 Created on 01 05 2014 Page 24 Maintenance TSM Control console connections Load cell connection Load cell B is only used if a second load cell is needed Modbus comms Reset Button See wiring table Slide valve 1 address on next page Slide valve 2 Slide valve 3 Slide valve 4 Alarm Clean Weight hopper ixing Motor USB REV A7 Created on 01 05 2014 Page 25 Maintenance TSM Connecting a Side feeder or Dispensing aid The valve outputs are sent to the valve block via Conn 12 These outputs are duplicated on Conn 14 Conn14 can be used to connect a side feeder to a blender or to connect a dispensing aid Vibrator or agitator For example to connect a Micradose side feeder as component 5 on a standard TSM 350 You would connect it to pins 6 GND and 7 24v output If an agitator is used on Component 1 then the agitator would be switched on using Conn 14 pins 1 and pin 6 This means that the agitator will only operate when the component is activated 14 Optimix Optimix Optimix Optimix 50 150 350 650 350 650clean 1000 1500 2
55. network or any of the other TSM options that can be connected You can also see if some other external items are connected to the main board Serial network port 9000 TCP Ethernet port SEI Extrusion control card SEI card LLS Low Level Sensor card for reading the bin sensors OPT Optimization special function V 1 Vacuum loading integrated loading only WD Watch Dog Timer Used to prevent the software from freezing or crashing REV A6 Created on 01 05 2014 Page 3 User manual TSM Blender Operation Before operating the blender should be configured and the calibration of the weigh hopper checked See the quick start guide in this manual for more details Check the correct materials are in the material bins Verify that the mixing chamber door is closed please refer to the blender safety information in the introduction section page 3 5 and that the air supply is connected Switch Power on the blender using the switch located on the side of the blender Enter the blend recipe setpoints Check that the blender is not paused See quick start guide on how to enter production setpoints REV A6 Created on 01 05 2014 Batch Blender Page 4 Batch Blender User manual Recipe Entry Please see the quick start section for recipe entry information Optional Auto Cleaning Cycle After a job is completed and before the next job changeover the TSM blender offers an opti
56. ntrol The module connects the blender to the extruder controls line speed device and roll change switches It should be mounted in the extruder control cabinet where it will be easily accessible to TSM engineers for diagnostics and servicing Line Speed Encoder optional weight per length control measures the film speed and the length of film produced The line speed device should be mounted on a film driven roller as close to the winder as possible Roll Change Inputs for customer supplied switches The system is equipped with two reel change inputs one for each of the front and back winders These inputs be connected to two normally open switches switches momentarily close connecting to ground whenever a roll change occurs The switches can be microswitches that are activated automatically by the removal of the roll or the cutting mechanism or a manually operated push button used by the operator The latter method is prone to errors from delays in pushing the buttons If the winder is equipped for automatic roll changes then spare relay contacts are usually available from the roll change mechanism HEV A6 Created on 01 05 2014 Page 10 Introduction TSM Optimix 50 150 Number of Components 4 Slide Gates No Side Feeders x Throughput per hour x 50 150 kg x 110 330 Ibs x Batch Size x 0 6 0 8 kg x 1 3 1 7 lbs Max Components 4 Discharge Valves 4 Max screw Feeders N
57. oader and or material conveying pipes Cable shields must be properly connected at one end of the cable only Note Ensure that all TSM System cables are connected before switching power on Do not connect or disconnect TSM system cables while power is ON HEV A6 Created on 01 05 2014 Page 21 TSM Quick Start Initial Setup Starting the Blender The following sequence should be completed on initial power up of the blender 1 Power up Home screen e Connect mains power lead Please read the safety information in the introduction section for warnings and the maintenance meum section page26 29 for the electrical prem 02 00 00 connections RE bs e Check that the operator display is showing the home screen biis e he TSM blender range are designed to allow easy operation for operators of all nationalities The system operation therefor uses internationallly recognised symbols See user manual for symbol descriptions Touching the home icon allows the user to return to the home screen from any screen 2 Weight hopper Calibration Front door of the blender must be open to calibrate the load cell e Touch ouch X e Enter the supervisor password Factory default password is set to 5560 System menu WARNING oome the system parameters can be changed from the calibration menu so it is advisable to restrict the number of personnel who have access to the password H
58. ockable hinged access doors allows you to see the batching cycle A safety interlock inhibits operation of the slide gates and mixing mechanism E Control Consoles All electrics pneumatics required for operating the fill valves and mixing motor are located in the electronics consoles mounted at the rear of the blender frame Auger Mixing Chamber When uncovered a level sensor inside the mixing chamber signals for more material Material drops into the mixing chamber where the mix auger runs continuously The patented positive displacement reverse mixing auger provides improved uniformity of Mixing Auger Access window door The material bins are equipped with finger guards These should never be removed Unless adequate precautions are taken to secure the Perspex door see page 4 4H d IN Removable Weigh Hopper A bracket attached to the load cell supports the weigh hopper All material that enters this hopper is weighed therefore the hopper must sit freely on this bracket with no obstructions in any direction The dump flap and accompanying piston should be visible when looking through the transparent door of the blender The weigh the blend with no material hopper slides for easy separation The auger is removable without tools for easy cleaning Page 8 Introduction TS Batch Blender Features and Options The Operator touch panel allows na
59. on 01 05 2014 TSM SEI Extrusion Control The extrusion control function is provided using the Serial Extruder Interface card SEI The SEI provides the necessary interface to the drive for extruder control This module is connected to the NBB electronics module Conn 3 via an eight core shielded cable For weight per length control it is necessary to connect a line speed encoder to the SEI card The SEI card provides the following functionality e Produces 0 10 volts to control the Extruder drive on connector Conn12 e Line speed encoder is connected to Conn 7 to allow the s Caro blender to measure the haul off line speed The card is din rail mounted and its dimensions are 190mmX105mmx35mm e Front Back roll change contact inputs may be connected to connector Conne to allow Roll Reports to be generated e The TSM Remote Auto Increase Decrease module may be connected to Conn9 on the SEI e Relay to prevent extruder start if the voltage to the drive is not below a safe value NOTE The Start Up relay contacts on the SEI are only closed when the screw speed set point is 596 The operator can therefore only start the extruder when the drive control voltage from the blender has been reduced below the 5 output level and thus this relay is e Test line speed signal for diagnostic purposes Extrusion Control Rev7 01 05 2014 Page 1 TSM SEI Procedure for connection of SEI module 1 If a line speed
60. onal simple easy to use the cleaning facility The blender may clean itself automatically on recipe change or after a manual request via the operator panel Mixer Cleaning upon Recipe Change e Touch ES the home page and continue change existing recipe or Select from memory by keying in job number e The cleaning cycle can be enabled e Atthe end of the cleaning cycle blender display returns to Production Summary screen e For molding the blender is paused and the operator presses 1 to continue the cleaning process Press Restart to commence new recipe HEV A6 Created on 01 05 2014 Page 5 User manual Batch Blender Using page numbers Each page displayed on the operator panel has a unique page number for easy reference The user may select a particular page number to go to that page the supervisor password is needed to use this function Touch the page number on the top left of the page as shown Touch this icon and enter the page E number j Touch this icon and enter the supervisor password 4 Touch this icon to confirm Sample page numbers Load cell caibration 191 Setting the Time 22 Software update 164 Communications diagnostics 37 Blender Self test 217 HEV A6 Created on 01 05 2014 Page 6 User manual TSM Batch Blender Alarms lf an alarm occurs an icon will appear on the blender icon on the home screen and the
61. ontrol Ace Hynass Feed valve REV A6 Created on 01 05 2014 Page 9 User manual TSM Batch Blender Cleaning status optional This screen allows the operator to view what parts of the cleaning cycle are active inactive Totals The Totals screen is used to display the 1 Current total This is a reset able total 2 Running throughout of the blender This oo total is only reset if the blender IS nem en powered off It is used to display the 3 173 8592 173 8592 overall throughput of the blender 231 8659 8 Heset the current totals rre bitii S688 REV A6 Created on 01 05 2014 Page 10 User manual The system menu contains all the calibration options primarily used during initial setup and before normal operation As all system parameters can be changed from this menu a password is required for access from the Main Menu IMPORTANT We recommend that you restrict access to the supervisor password to supervisor management personnel the Engineering password to technical personnel Ihe Password are shown on page 2 of this manual From the System Menu you can e Calibrate the weigh hopper Set the time and date e Run the blender self test e Set and change the blender password e Update the blender software e Enable printing saving to USB of all reports e Enable the diagnostic logs TELNET e View communications between devices Operator panel SE
62. or safety interlock which removes the Electrical power and discharges compressed air from the slide gates CAUTION Flying objects This blender is equipped with a compressed air gun that can be used for cleaning the bins and mix chamber To avoid potential injury you must observe all safety regulations that apply to the use of compressed air for cleaning equipment Adjust air pressure to no more than 7 5 Bar 100 PSI for auger mixing systems Wear protective goggles and clothing to prevent injury from flying particles and objects When you change materials you should clean all interior surfaces of the blender thoroughly using a clean cloth vacuum or compressed air otop the blender then disconnect the mains power lock out the main power source e Drain the material bins using Optional easy drain valves e Open the bin access doors and remove all material using compressed air or vacuum e Open the mixing chamber door and disconnect the weight hopper and remove same Clean the weigh hopper e For Optimix series blenders Remove the front plate of the mixing chamber and stainless steel mixing chamber liner e Empty residual material and clean the mixing chamber You have the option of removing the mixing auger if necessary REV A7 Created on 01 05 2014 Page 2 Maintenance TSM Batch Blender e Slide the weigh hopper back into the mix chamber making sure that no obstructions prevent the hopper from resting evenly o
63. p to 10096 HEV A7 Created on 01 05 2014 Page 9 Maintenance Continued Batch Blender oystem Alarms Alarm message Possible cause Solution FO the load cell weight has not being tared to zero Tare alarm During the cycle the system could not empty the hopper within 20 seconds Low Level alarm optional This alarm is only activated if low level sensors are fitted to the reservoir bin and connected into the system through the Input card 96 Deviation alarm he actual percentage of component is not correct not suitable Software security alarm NBB Software License timeout A component in the reservoir bin has fallen below the pre set level I Non free flowing material can cause this or dosing the material through a valve that is The software cannot 4 NBB HAETSM read the necessary information from the ES There is problem on calibration of the load cell the should be checked See Calibrating the Weigh Hopper in the quick start guide page 1 Check that the dump flap below the weigh hopper is opening correctly and that is not touching the material in the mixing chamber Add more material to the reservoir bin as required E Check the introduction section for the min and max percentages for each size of valve and verify that the set percentage 15 within spec Check that
64. quipment off e solate the equipment from electrical power e Turn the rotary disconnect switch anti clockwise to Off position Secure the device with an assigned lock or tag e he equipment is now locked out The single phase Blenders The single phase blenders are not supplied with a lockout switch so they should be powered off and the power cable removed before any electrical work is carried out TSM recommends that the single phase blenders are connected using a customer supplied lockout switch WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been removed and all safety guards reinstalled HEV A6 Created on 01 05 2014 Page 5 Introduction TS Batch Blender Description How It works IN 7 Features and options IN 9 Specifications IN 1 1 Unpacking IN 12 Mounting Equipment IN 13 Connecting Power amp Air IN 14 Configuring Blender Throughputs IN 15 REV A6 Created on 01 05 2014 Page 6 Introduction Batch Blender How It Works Operator touch panel Production Summary 003C 00 ay 0 AM p 009 ULM Using the touch screen panel the operator enters the recipe as a percentage of each component or material When it is started the blender will start the mixing motor Close the weight hopper and open the slide valves in turn to dispense the correct percentages of
65. r 4s x Caution changes to any settings inside this area may stop the blender or cause it to function incorrectly REV A6 Created on 01 05 2014 Page 20 User manual TSM Batch Blender Setting the Blender IP address Touch the Icon Enter the password 9335 Metweork Icon Then touch the icon Touch the urrant IP 000 00D 000 000 Fixed MAC 00 00 00 00 00 00 Touch as shown to set the network settings IP 010 000 000 250 Subnet 255 275 000 000 Touch the Save Icon when finished Gateway 000 e 9 000 DNS 000 000 000 000 Gm REV A6 Created on 01 05 2014 Page 21 User manual Batch Blender Mode The four options in the Mode menu they can be used to otop the blender cycling immediately Allow the blender to finish the current batch drop it and then stop gt Restart the blender Manually start the cleaning option WARNING The above options do not stop the mixing motor HEV A6 Created on 01 05 2014 Page 22 User manual TSM Batch Blender Setting a license Some options are licensed and therefore can only be changed by getting a licensed code from TSM Touch the gt icon to open co this Screen Syston 00 1200 Panel bp 3 222 an 00 00 n T Q D kg a oO 000000 WU DOU ODD UJU WU Ll ad 00 00 00 OD x wn
66. red beacon mounted on the blender frame will provide a visual warning Some alarms may cause the blender to enter manual mode To find the cause of an alarm touch the alarm icon on the home screen This page displays any alarm that has occurred or cleared the time at which it happened and it s current status To remove alarms touch the X icon Alarm Occurred PN goose DD ALAS G E ra 9 4 0 90 00 DO DQ 00 oO Alarm Cleared 4 Note Alarm s clear every time the blender is powered off For the alarm description see page 5 of the quick start section For more detailed information what each alarm message means and how to troubleshoot the alarm see the TROUBLESHOOTING section of this manual There is a position on the NBB board to connect an external alarm see maintenance section for a diagram This connection is a set of relay contacts and the external alarm should have an alternate power supply Do not try power this alarm from the NBB board HEV A6 Created on 01 05 2014 Page 7 Batch Blender User manual Reports The Reports Menu allows you to view various reports generated by the blender A sample of each report can be found on the following pages To access any of these screens touch the reports icon on the home screen and then the appropriate icon for the page you wish to view Current order This report allows you to check the status of the cur
67. rent order You can also reset the production order totals Resetting order totals can be useful for example in the extrusion process when you have to discard a start up roll of scrap material that should not be included in the order total Touch X to reset the order totals Order Report The report shows all of the values for the previously completed order In order to use the order reports correctly the order totals should be reset when starting a new recipe gt gt 8 To reset the totals tick this box REV A6 Created on 01 05 2014 Page 8 Batch Blender User manual D Roll Report If the roll change signals are connected to the SEI card this report shows all of the values for the previously completed roll including Start time Finish time Length Component weight Total roll weight 2 de Blender information On this screen it is possible to view the set and actual batch weights along with the open close status of the fill valve for each component configured Slide gate 1 open 0 0000 ggg 0 0007 4 If the blender is paused the slide valves and weight hopper dump flap can be manually opened closed by touching the icon The valve will stay open until manually closed Lycle Blender Cleaning Mixer Cleaning Disabiec Mixer Laver Sen amp or Active Maternal Flow Sensar Active Neck Arva Flow C
68. rror something has caused running beside any on the comms counters then there is a the SEI card to reset high voltage cable problem SEI Loose connection on Check that all of the connections are ndn the comms cable ok between the NBB and the SEI card SEI comms alarm Verify that the run LED on the SEI A loose connection card is flashing and the 24v led is on between the SEI card The comms counters can be seen on and the NBB card the diagnostics screen poe MESS Is the throughput too iZlVerify that the correct target set high for the blender or points for components and throughput extruder screw Is have been entered there excessive Verify that the blender and feeders Unable to Control Blend vibration are correctly sized to satisfy the The blender was unable throughput for this application to control the throughput t IVerify that the extruder can satisfy to the required set point the throughput for this application or it was unable to stay Excessive vibration can also cause within the control dead control alarms band TSM Control Systems if you Suspect vibration is the problem Is the line speed stable Verify that the blender is reading the correct line speed from the line speed encoder and that the speed is stable The blender can cope with small changes in line speed but a large change will result in this alarm Is the cable shield ok Is the encoder making good contact with
69. rt and instillation Operation Maintenance and repair Fault finding Take particular note of The chapter containing the warning notes in the manual Layout of the manual This manual is classified into several main parts e User information e Safety Technical specifications ransport and setup e otructure and function Operation e Maintenance and repair e Decommissioning and disposal Appendix menu structure REV A6 Created on 01 05 2014 Page 2 Introduction TS Batch Blender TSM design equipment with the user s safety in mind You can avoid potential hazards identified on this machine by applying common sense safety precautions and by following the procedures outlined below and elsewhere in the Operator Guide Meaning of safety information oafety instructions are placed before the work steps Read the safety instructions carefully before carrying out the subsequent operation If safety instructions are not followed serious personal injury possibly with fatal results and property and environmental damage may occur The safety instruction in this operating manual are indicated with a symbol The symbol contains a signal word indicating how serious the danger is AN WARNING Improper installation operation or servicing may result personal injury or equipment damage This equipment should be installed adjusted and serviced by qualified technical personnel who are f
70. s it cools 2 Vertical haul off When using this type of process it is necessary to mount the line speed encoder close to or on the nip roll The reason for this is that the vertical haul off causes the winder speed to vary depending on the direction of rotation Line speed encoder The above diagram shows two suggested position for the line speed encoder Either of these rollers is ideal as the film is being pulled around the roller so it should not slip on this roller The reasons why this position is better than on the tower 1 This is more likely to be the final speed of the film taking into account stretching or shrinking 2 The line speed encoder cable also contains 3 extra cores for the roll change signals and the signals are available at the winder 3 The reason why we have pointed these rollers out as the ideal position is that the film is turning through 90 degrees on these rollers so there is good contact between the film and the roller These rollers are film driven and therefore are moving at the film speed A motor driven roller could have some slippage 4 The encoder is in better position for trouble shooting Extrusion Control Rev7 01 05 2014 Page 13 0 gu SUPPLIED BY GUSTOMER i t a m HACKET BE ganddns inW own a O a D Dy 5 D G U D U ELEVATION ELEVATIOHN Page 14 01 05 2014 Extrusion Control Rev7 TSM
71. set points oetting up g m control otarting the Extruder SEI diagram Extruder Start Switch Change Over Switch Mounting the Line Speed Encoder Co Extrusion Connections Common start up issues IN 2 IN 3 IN 5 IN 7 IN 8 IN 9 IN 11 IN 13 IN 15 IN 16 IN 17 IN 18 IN 19 IN 20 IN 22 95 1 95 1 25 2 25 2 25 3 25 5 95 6 Ex 1 Ex 2 Ex 3 Ex 4 Ex 5 Ex 6 Ex 7 Ex 8 Ex 9 Ex 10 Ex 11 Ex 12 Ex 13 Ex 14 Table Of Contents Operation Touch screen panel overview Home Screen Passwords User Manual Blender information screen Blender Home screen Passwords Information Icon Blender operation Recipe Entry Auto cleaning option Using page numbers Alarms Reports Blender information System configuration Load cell Calibration Diagnostics Report printing saving Logging to SD card Telnet Blender Self Test Time Passwords Updating software configuration Integrated loading TSM Engineering password Setting the Network Address Mode Maintenance Preventative maintenance schedule Cleaning the blender Troubleshooting Foreword Word of caution Determining the cause of a problem Component alarms System alarms Checking the loadcell Checking and replacing slide gates Checking and replacing feeders Calibrating the operator touch panel Frequently Asked Questions UM 1 UM 2 UM 1 1 UM 12 UM 14 UM 14 UM 15 UM 16 UM 16 UM 17 UM 18 UM 19 UM 20 UM 21 2
72. show standard slide valve size configurations If a lower is required for any component the appropriate insert medium 50mm 2 inch or small 38 mm 1 5 inch must be inserted Please refer to page12 13 for the physical layout of the standard material bins for the TSM blender range COMPONENT MIN MAX SLIDE VALVE INSERT 1 5 4 1 110 0 100 40 50 2 10 70 40mmx50mm None 3 0 6 30 Restricted Restricted 4 0 6 30 Restricted Restricted COMPONENT MIN MAX SLIDE VALVE INSERT L NO 1 SE 1 110 0 100 40mmx50mm None 2 10 70 40mmx50mm None 3 0 6 30 Restricted Restricted 4 0 6 30 Restricted Restricted LL 76 1 10 100 75mm None 2 5 0 100 75mm Medium 50 mm 3 5 0 70 50mm None 4 10 6 15 50mm Small 38mm REV A6 Created on 01 05 2014 Page 19 Introduction Optimix 1000 Batch Size 7 5Kg Optimix 1600 Batch Size 12Kg COMPONENT MIN MAX SLIDE VALVE INSERT SIZE NO 25 SIZE 1 10 0 100 75mm None 2 10 0 100 75mm None 3 50 70 75mm Medium 50mm 4 10 5 15 75mm Small 38mm NO SIZE 1 110 0 100 100mm None 2 110 0 100 100mm None 3 10 0 100 100mm None 4 110 0 100 100mm None 5 10 0 100 100mm None 6 0 2 15 100mm Medium 50mm If small insert is 0 1 15 100mm omall 25 mm used NO _ 1 6858 4 1 10 0 100 75mm None 2 10 0 100 75mm None
73. stopped 1 Load cell This switches a test voltage into the load cell input and verifies that the blender Is reading it correctly 2 A D Stability test is run for 10 seconds to verify that the load cell is not drifting 3 Hopper tests the load cell s tare value is within range of its original value 4 Component tare Reads the load cell between each component filling to ensure there is no drift from the time a component stops filling and the next component starts filling 5 Tare Dev reads the load cell tare value after each batch and compares it to the previous batch A change greater than 200 counts will fail 6 Cal Const Tests the load cell s Calibration constant is within range of its original value 7 Component Retry Check the number of retries on each component in the previous hour More than 10 retries will fail 8 Std Dev s Checks that each of the components are filling within range 9 Memory Writes and then reads back a block of text to memory 10 SD Card this writes some text to the SD card and reads it back 11 Events This will fail if any of the next 3 alarms fail 12 Alarms Test fails if any tare alarms have occurred in the last 24 hours 13 Leak Alarms Test is deemed to have failed if any leak alarms in the last 24 hours 14 Dump Flaps Test fails if any weigh hopper dump flap alarms in the last 24 hours 15 Comm Panel 16 Comm SEI Communication is checked over a 2 second period if th
74. system could not empty the er 0 hopper within 20 seconds The weigh hopper did not open 300 Check the hopper piston and the solenoid valve that supplies the piston The load cell had reached its max value 302 None Minimum opening time exceeded A 96 that is too 304 None small for the component has been entered 9 Created on 01 05 2014 Page 5 Quick Start Code Alarm Icon Description Fault with the AD part of the board The load cell 307 None will not function The load cell reading has gone negative 308 None A zero weight had been used to calibrate the 309 None weight hopper load cell Ultrasonic sensor is not functioning correctly if 323 None fitted Bypass Valve opened alarm 324 None HEV 9 Created on 01 05 2014 Page 6 TSM Quick Start Extrusion Haul off Control Alarms See extrusion control section for full description and additional alarms Alarm Icon The line speed has gone zero 32 mimin Check the displayed line speed p The blender has not been able to control to the 64 Control alarm current set point The communications to the SEI card have SEI communications alarm stopped working SEI Reset Something has caused the SEI card to reset Extruder shutdown by blender If this option is enabled and the blen
75. the roller P The line speed encoder Check that the line speed encoder can m min 0 is not rotating or there move freely and that all of the Zero Line Speed is a loose connection at connections are ok the encoder or at the SEI card Extrusion Control Rev7 01 05 2014 Page 16
76. the weigh hopper by opening the door of the blender remove the weight hopper and manually open the slide gate 5 2 22 5 a a Did the air actuated slide _ Verify that the RUN STOP switch is in the RUN position Verify that the valve is connected to compressed air supplying at least 6 0 bar 87 PSI m Verify that the solenoid and relay is working correctly See Checking Fill Valves page 12 that feeder cable connections in the blender wiring cabinet are secure Verify that the feeder solenoid light turns on 7 Maintenance TSM Batch Blender When a problem affecting the blender control or more than one oystem Alarms component occurs The blender automatically enters manual control mode after a period of time if the alarm is not resolved Alarm message Possible cause Was there a component fill alarm Level Sensor Uncovered The level sensor in the mixing chamber failed to see material during a fill cycle E Is the level sensor faulty REV A7 Created on 01 05 2014 Solution A component may not have filled correctly causing the weigh hopper to delay dumping the next batch into the mix chamber Verify that component bins and feeders have material are operating correctly and that the loading system can maintain all components This is an important alarm because it is possible that the extruder was starved of mat
77. there is no material blockage above the slide valve It may be necessary to add a Vibrator or paddle This cannot be resolved without returning the NBB to TSM EBENE IV z n Ys a L rr A six r aai There have beena Contact 5 for a new License A ricenses temporary software license installed code HEV A7 Created on 01 05 2014 Page 10 Maintenance TSM Batch Blender Load Cell Checks and Calibration A malfunctioning load cell can lead to incorrect batch weights and persistent A D Error alarms problem may be caused by material trapped around the load cell housing failure on the NBB control board electrical noise or a damaged load cell To check the load cell e Power up the blender using the mains power switch located on the side of the blender Open the front door of the blender as the load cell cannot be tared zeroed when the door is closed Clean the weigh hopper and load cell area Open the mixing chamber door and slide the weigh hopper out Using the supplied air gun clean the hopper and any dust that may be around the load cell Ensure that there are no granules trapped around the load cell and ensure that the weigh hopper is not being obstructed e Check the mounting bolts for the load cell and bracket These bolts must be securely tightened Two bolts mount the load cell to the block Four bolts mount the block to the top plate of the blender chassis Verify that t
78. tomer HEV A7 Created on 01 05 2014 Page 21 Maintenance TSM Our service experts are available to help with any problem you might have installing and operating your equipment TSM Control Systems also offer a comprehensive on site installation training and preventative maintenance programme You can contact our Customer Service Department by any of the following methods Tel 353 42 93 35 560 Fax 353 42 93 34 422 Email support tsm control com You can commission TSM Control Systems service personnel to provide on site service by contacting the Customer Service Department Should you encounter a problem commissioning or operating the blender please complete the following checklist before contacting 5 Control oystems 1 Ensure you have all model numbers and serial numbers for your equipment Service personnel will need this information to assist you 1 Check that power is supplied to the equipment see p age 18 in the introduction section L Check that all connectors and wires between the control console and related components have been installed correctly as per the wiring diagram in this manual 1 Please refer to the troubleshooting guide of this manual Section page15 which may assist in solving the problems Examine the instruction manual s carefully for associated equipment especially controls Each manual has its own troubleshooting guide to help you 1 Check that the equipment has been
79. uration area Supervisor password Default 5560 This allows access to the calibration and diagnostics area Operator protection Default 1 This allows the operator access to the recipe area REV A6 Created on 01 05 2014 Page 2 User manual TSM Batch Blender Blender information icon 2 At the top right of the home screen you can see the blender information icon Touching this icon allows the user to see the critical blender information Please take note of the information in this screen before contacting TSM with support issues This screen can be very useful when trouble shooting the blender as well as the blender type IP address and software version you can also see the last power up time and the number of batches Oo OE the blender has made since the power up vue x Dn F 00 00 00 00 t c 6 0 hy 5 SD card 00000000 00 000000 SD card is in position Subnet 000 200 002 55 226 _ ies di SD card is not in position F dia pu Touching allows the SD card to be safely removed This will disable the SD card write function for 30 seconds Warning Never remove the SD card without disabling it first or the contents can get corrupted ih i The icon allows you to see what options are enabled disabled see setting the license section of this manual for further information In the right column you can see the board temperature and also if the blender is communicating to a
80. vigation through the system Refer to main user guide for details Features 7 TFT Widescreen Resolution 800x480 pixels Touch screen Type 4 wire analog restive Simplified operator screens Enter and store blend recipes by percentage of components On completion of one job east transition to the next job and recipe Real time production status report summaries are available oetpoints actual weights per component and average throughput are also available For extrusion purposes the total length thickness roll and order reports can be displayed Printed reports include time date order number and material usage Password protection of all blending system parameters Remote mounting Supplied with 3 meters 10 Ft of cable standard Material Flow Reducers specified at time of order may be fitted to the material bin slide valves to improve the dispensing accuracy of components with small target weights Please refer to section IN 17 for more Information Flow Control Valve off line blending A pinch or flow control valve must be installed between the mixing chamber discharge and the container or distribution system This valve ensures proper mixing by controlling the material flow from the mixing chamber REV A6 Created on 01 05 2014 Page 9 Introduction TS Batch Blender For Extrusion Applications Serial Extruder Interface yield control option Used for on line blending with extrusion co

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