Start up Guide - TSM Control Systems
Contents
1. AD Counts Factory default password is set to 5 6115 A D Max 21932 1 2 1 Taring the weight to zero Weight Lb 1000 11023 0 0 70 Ensure that the mixing chamber door is open and the weigh hopper is empty and there is Fill Target Weight Lb 6500 00 nothing touching the weigh hopper before taring the load cell Tar Weight Averaging 1 3 d Double Dump Disabled Press to set the weight to zero vu Tare Calibrate S R 1 2 2 Weight Calibration Gently slide the weigh hopper out and place a known weight into it use a weight close to the batch size PLC Start up Rev 1 1 Page 3 Touch the position marked opposite and if for example the calibration weight is 116 enter 1000 0 on the numeric keypad The actual weight should show 1000 0 lbs If it is required to calibrate again this can be done Calibrate by pressing Remove the weight from weigh hopper The weight should now return to zero If this does not return to zero then this indicates a possible weighing problem The fill target weight is the weight that the blender will fill the weigh hopper to when all components have been filled Checking load cell repeatability a SIM Control Systems AD Counts A D Min 6115 A D Max 21932 Weight Lb 1000 11023 0 0 70 Fill Target Weight Lb oni Weight Averaging 1 3 d Double Dump Disabled Calibrate Back Tare Another check that can be done on the load c2. First Component Compensation When enabled the first component is used as a reference for all other components If it under fills the other components are adjusted to keep the first component accurate High accuracy mode The high accuracy mode ensures that the main component and the top up reference component ratio is kept very accurate 1 5 9 Screen 2 Bypass mode SCH SHERSISHE SE RSS Hinc L This mode if enabled will enable the Bypass Mode Disabled bypass to be activated when the sensor in Double Dump Disabled the next of the blender is uncovered fora imperial Metric Imperial period of time Auto Cycler Disabled Weight Calculation Round Robin Double Dump Offline Valve time 0 Allways Open 0 This option allows the blender to open and Sensitivity 1 close the dump flap on the weigh hopper Settles Sampling Period 100 twice when dumping This helps to Vacuum System Enabled dislodge any granules that have become Max Batch Weight 9999 stuck on the weigh hopper Production Summary Units There are two options available Metric or Imperial Auto cycler This is a test mode only used for program testing and should not be switched into this mode at any time PLC Batch Blender User Guide Rev 1 1 Page 12 QE TSM Batch Blender Control Systems User manual Weight Calculation This option allows the blender to run in Round Robin or volumetric mode Offline Mixing time This is the time that the offline valve sta
3. From the System Menu you can Calibrate the weigh hopper Set and change the blender password Edit the configuration Start the Cleaning additional option Set the max and min flow rates Cleaning Config Weight PLC Batch Blender User Guide Rev 1 1 Page 9 TSM Batch Blender QE TSM Batch Blender Control Systems User manual 1 5 1 Load Cell Calibration Weight Press to access the load cell calibration This is show in the quick start guide 1 5 2 Passwords This screen can be used to change the operator and supervisor passwords 1 5 3 Operator password T RIT HENNE This allows the operator access into the recipe Section Supervisor Password d 1 5 4 Supervisor password This allows the supervisor into the recipe section Lack and also the system settings This password should be restricted to authorised personnel as it allows access to the blender calibration settings see the quick start section of this manual for the factory set passwords NOTE It is important to make a note of the new passwords 1 5 5 Cleaning Cleaning is unused at the moment the only parameter that needs to be set is Bypass Activation Delay Secs This delay in seconds specifies the time after which the blender will open the bypass valve after the bypass sensor has become uncovered On Time 5 Off Time 5 Repetitions Bypass Time Limit Bypass Activation PLC Batch Blender User Guide Rev 1 1 Pag
4. The weight should be displayed on the Hopper Calibration page If the displayed weight is correct gently pull down on the hopper and release it The weight reading should return to the correct reading Repeat this process 2 3 times Now remove the weight and allow the weigh hopper to go back to zero If the reading does not go back to zero there is a problem with the load cell The AD readings from the load cell are displayed on the hopper calibration page The tare ad readings are also displayed When you tare the hopper the actual readings and the tare readings should remain within 5 counts of each other If the ad readings drift more than this then the load cell is not working correctly check the items listed below Fluctuations in Check that the hopper does not come in contact with the frame and that it is Weight Check the operation of the load cell weight readings positioned properly on the bracket Make sure the air pipe going to the hopper is free and has a gradual loop to the piston on the dump flap If this pipe is too short it may affect the readings This can be verified by removing the pipe during calibration Check that the load cell mounting bolts are securely tightened Two bolts mount the load cell to the block which in turn mounts to the blender top plate Carefully check that the load cell cannot move from side to side on the mounting block Check also that the bolts securing the weigh hopper mounting brac
5. 2 Password Setting All TSM blenders include 2 levels of password protection Engineer Password Default 5 This allows access to the blender configuration Calibration area Operator protection Default 5 This allows the operator access to the recipe area PLC Batch Blender User Guide Rev 1 1 Page 4 User manual QE TSM Batch Blender Control Systems 1 3 Blender Operation checks Before operating the blender should be configured and the calibration of the weigh hopper checked See the guick start guide in this manual for more details Check the correct materials are in the material bins Verify that the air supply is connected Switch Power on the blender using the switch located on the side ot the blender Enter the blend recipe setpoints Check that the blender is not paused See guick start guide on how to enter production setpoints PLC Batch Blender User Guide Rev 1 1 Page 5 Nam a TSM Batch Blender Control Systems User manual 1 3 1 Recipe Entry Press to select recipe entry Please see the quick start section for recipe entry instructions 1 3 1 1 1 Lb hr 718 37 1 3 2 Blender alarms If an alarm occurs an AA icon will appear on the blender home screen as shown and the red beacon mounted on the blender frame will provide a visual warning 1 34 09 PM To find the cause of an alarm touch the alarm icon on the home screen This page displays any ala
6. Ensure that the mounting bracket and weigh hopper are not touching the sides of the blender frame 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 the 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 Check slide valve guards If 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 Check stability of reading If the weight reading is not stable or if you have to carry out the calibration more than once a month contact TSM Support Services for further instructions Please note that a faulty load cell will still calibrate so it is essential to check that the load cell is weighing correctly See Quick Start Guide for information on checking load cell stability Rev 1 2 PLC Batch Blender 20 12 11 Page 10 KR A Control Systems 1 10 Checking Component Fill Valve operation There is one air operated slide valve associated with each compartment of the material bin oolenoids located on the back of the blender control the slide valves SC Blender I
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8. 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 Rev 1 2 PLC Batch Blender 20 12 11 Page 16 are Control S sterne 1 11 Removing mixing screw To remove mixing screw do the following see Fig 1 2 3 e Ensure that air and power is removed from the blender e Open the hex screws to remove the end plate M Fig 2 Removing screws on left hand side Fig 3 Remove screws on right hand side Page 17 R A TSM Control Systems Page 18 DTUEL TSM Control Systems 2 Customer Support Our service experts are available to help with any problem you might have installing and operating your eguipment 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 TSM Control oystems e Ensure you have all model numbers and serial numbers for your equipment e Service personnel will need this information t
9. be handled in such a way that the load cell could be damaged This includes hammering the frame and exerting excessive force on the weigh hopper At no time should the load cell be exposed to high temperature The load cell calibration should be checked at every two months for correct operation or if the blender is not dispensing accurately at any time Failure to do this could result in production errors or losses Please refer to the quick start section of this manual on how to calibrate the load cell 1 5 Cleaning blender during material change 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 Rev 1 2 PLC Batch Blender 20 12 11 Page 4 nt A Control Systems 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
10. been equipped with the lockout device pictured below To use the lockout device on Rev 1 2 PLC Batch Blender 20 12 11 Page 3 ae A TSM Control Systems 1 2 Resolving issues Most problems can be avoided by following the recommended installation operation and maintenance procedures outlined in this User Guide If there is a problem this section will help determine what caused it and how to fix it 1 3 Maintenance checks Weekly 1 Check air regulator filters for condensation or other signs of water Purge and clean the filter bowl if necessary Monthly Inspect power cables wires and electrical connections Check for loose or exposed wires burned contacts and signs of damaged wires Check exterior power cords to the main power source Inspect air connections hoses lines for wear or damage Tighten connections or replace damaged parts Check for granules trapped between fixed parts and gravimetric weigh hopper and bracket eS en Every two Monthly 1 Check load cell calibration 2 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 3 Ifthe mix auger flights become sharp or damaged through wear replace it 1 4 Load cell calibration Warning The load cell is susceptible to damage if it is not handled with care At no time should the blender
11. can move freely Rev 1 2 PLC Batch Blender 20 12 11 Page 11 LUE Control Systems Wiring Considerations Blender is not Check the electrical main connections to the Frequently powering up blender as per the electrical wiring diagram Asked ELE Questions Do NOT run TSM The wires connecting the various elements of a cables with high TSM system are normally communications data voltage cables 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 advisable from a safety and aesthetic point of view Why is it Moving plastic granules can produce extreme necessary to static charges keep If pipes carrying the granules are not properly communications earthed then the electrical energy will be cables and discharged down through the system electronics material causing possible malfunction and damage conveying lines Generally static symptoms include the resetting of separate 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 or other conduit containing cables with high voltages or high currents If possible run the communications lines
12. to prevent injury from flying particles and objects Note that the air pressure is very important particularly for components that are dispensing small percentages At regular intervals open the moisture trap to drain water that might have entered the air system When you change materials you should clean all interior surfaces of the blender thoroughly using a clean cloth vacuum or compressed air The procedure is as follows Stop the blender e Ensure that the air and electrical supply is removed from the blender e Remove 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 Empty residual material and clean the mixing chamber You have the option of removing the mixing auger if necessary e Slide the weigh hopper back into the mix chamber making sure that no obstructions prevent the hopper from resting evenly on the load cell bracket Don t forget to put the air pipe back on the weigh hopper Close the material bin doors and the mixing chamber door Apply air and power on the blender again The blender is now ready to runr Rev 1 2 PLC Batch Blender 20 12 11 Page 5 QE CoA rol mde 1 6 Troubleshooting procedure e 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 con
13. 5 35 37 47 Page 3 REV 1 0 Created on 17 01 2012 12 00 00
14. alarm the max batch size would be exceeded Over fill alarm Blender dumped the batch due to the fact that it exceeded the maximum batch size when the components were filled The batch is dumped in this case Material starvation This indicates that the sensor in the mixing chamber was exposed before the blender was able to fill the weigh hopper with all component Mixing screw trip The mixing screw contactor has tripped due to over current Indicates that the bypass valve is being activated and the blender is being bypassed Table 1 0 Alarms description PLC Start up Rev 1 1 Page 6 ea E Start up Guide Control Systems 1 7 Common Start up Issues The common start up issues are shown in Table 2 0 not powering up blender as per the electrical diagram Check that the 24 volts is present in The blenderis Check that the mains voltage and 3 phase voltage is present onthe correctly the blender junction box Measurementis Ensure that the weigh hopper is empty It should display 0 kg lb if not not functioning tared zero the hopper following directions on page 2 in this manual the properly front door must be open for the calibration Check that the hopper is centrally located in the blender and that nothing is touching the hopper If the slide valves have been fitted with guards check that there is nothing trapped between them and the load cell bracket Now GENTLY place a weight in the hopper
15. ccurs on the blender a A Will appear on the blender bin and the red beacon mounted on the blender frame will provide a visual warning e To find the cause of an alarm go to the production summary screen and touch E The cause of the alarm and the time that it occurred will be displayed on the Alarm Summary screen e Touch Ack to cancel an alarm For information on what each alarm icon means refer to the diagnostic tables on the following pages Rev 1 2 PLC Batch Blender 20 12 11 Page a e i Control Systems 1 8 Causes and resolution of alarms Alarm message 1 8 1 1 1 8 1 2 1 8 1 3 Material starvation Fill alar m on com pon ent 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 Has material bridged over the bin discharge blocking material flow Did the air actuated slide valve for this component fail to open The level sensor in the mixing chamber was uncovered before it finished filling the material into the weigh hopper Is the level sensor in the mixing chamber functioning properly Rev 1 2 PLC Batch Blender 20 12 11 Solution 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 feeder or material slide valve openin
16. cipe and enter the regrind percentage Note that the regrind is entered outside the 100 for example Comp 1 10 regrind component Comp2 80 Comp3 20 1 4 Starting the new order Press La to start the new order and press w to confirm the new order transfer should take place PLC Start up Rev 1 1 Page 5 Recipe Order No Start up Guide Comp ID Nome 1 te chau ri altt 2 l 0 00 3 vistamaux 20 88 Ex T UCM EE TUR EET same Reset Totals X Start up Guide Control Systems 1 5 Start the blender if the blender is already paused will be J 4119 34AM Summan UE on the screen To start the blender T press Or M The following screen is then displayed Blender Paused Press D to start the blender cycling SAAST Now the blender should fill the component to Lb hr 718 37 the set component percentages as specified in N the current order Mode 1 6 System alarms If the alarm icon is present on the main summary screen this indicates that an alarm is present on the system Press MK to show the alarms that are present on the system Table 1 0 is a summary of all alarms in the system Description Fill alarm Component fill alarm The required amount of material did not fall through the slide gate The component number will also be displayed Non Conformance This alarm indicates that the batch was terminated due to the fact that
17. ck start guide FAQ section loadcell Rev 1 2 PLC Batch Blender 20 12 11 Page 13 Control Systems Frequently Other Accuracy issues Asked When feeding through the SLIDE VALVES My blender does not seem to be achieving the required accuracy Operator Panel The Operator Panel is not working what should do Other hardware If the mixing motor is not rotating The mixing motor does not seem to be rotating in the correct direction When the TSM blender leaves the factory it is set to a standard slide valve configuration unless Questions specified otherwise by the customer The slide valve size determines the minimum and maximum percentages that can be metered for each individual component If a lower is required for any component the appropriate insert must be attached oee blender valve size configurations Please Check Quick Start Guide FAQ Section Page 7 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 Rev 1 2 PLC Batch Blender 20 12 11 Page 14 ae A i arna what should do If the direction of the mixing auger is incorrect 3 phase models Switch mains power switch to off and lock it only out Disconnect mains power supply externally to blender Swap any 2 phases e g L1 amp L2 going to the blender Reconnect mains power and turn mains
18. d when working on any pneumatic part of the system 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 WARNING 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 Rev 1 2 PLC Batch Blender 20 12 11 Page 2 ma FIRE Control Systems 1 1 1 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
19. e 10 QE User manual Batch Blender Control Systems 1 5 6 Maximum and minimum flow rates Max min flow rates ensure that the blender cannot calculate an incorrect flow rate for a particular component Press L to show the flow rate page This page shows the max and min flow rates for each component The user should enter the max and min flow rates that they are expecting for the material that they are currently using If the system calculates a flow rate higher than the maximum then the flow rate will be clamped at the maximum If it calculates a flow rate that is lower than the minimum then it will clamp the flow rate at the minimum flow rate Comp Actual Max Min 1 4761 00 5000 3500 2 50 00 2000 50 A 216 00 300 100 Seal 1 5 7 Configuration The configuration allows the configuration for l 3ysten SELLING i e Latency mS 40 j the blender to be set Press to Mix Motor Shutoff Time mins 5 select page 1 of the system settings The Humber of Blends 3 various parameters are now described Fill Retry 0 Indefinately 2 Retry Recovery i 1 5 8 Screen 1 Regrind Fill Retry 0 Indefinately 0 Latency seconds Top Up Reference 3 This signifies the delay before the slide valve tie Time 2 switches This is normally set to 40 First Component Compensation Enabled milliseconds High Accuracy Mode Disabled Mixing Motor Shutoff minutes This entry determines the time after which the mixing motor will turn off
20. e eee eee e nennen 10 toz Fac W TTT 10 toS ODER AS SWO RR de EEN EEN Te Ek Eee AE eee ET EET bede 10 1 5 4 Supervisor password cccceeccccseececeeeecececceuceseeasceceueeeeseusessaeeseaeeeseueeessaeeeseas 10 tooa SANG ee 10 1 5 6 Maximum and minimum flow rates sese eee eee eee e eee 11 EO Cine Free 11 ITE 6 lt e I EET E ET E 11 1 5 9 SOTO EE 12 SEET SN ee 13 1 6 Pause and Restart Mode 14 PLC Batch Blender User Guide Rev 1 1 Page 1 QE User manual Batch Blender Control Systems 1 User Guide 1 1 General Description Operator touch panel gt 73 34 09 PM Summary ixer 4 H Production Summary Lb hr 718 37 Using the touch screen panel the operator enters the recipe percentages The normal blender slide gate configuration is component 1 Large opening component 2 Large opening component 3 Medium opening component 4 Small opening The percentages entered should reflect the component slide gate size I E component 1 should be used for larger percentages When the blender is powered on it will start the mixing motor Close the weight hopper and open the slide gates in turn to dispense the correct percentages of 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 next batch will drop and the cycle will start again If the blender encounters any problems the alarm ico
21. eal ESIM Start up Guide EE EELER EE 2 P te Ge ubi EE 2 T2 6 ghia g le 9 6 gt a eris MEE US RET 2 1 2 1 Taring tne WEIGNI 19 Te TN 3 1 22 Weight CANOGA OM BEE 3 I EAN INO oS 8707 71 CC 5 1 3 1 Regrind entry optional sss eee eee 5 1 4 Starting TNE NEW te 5 Te TR US 0 53 476 EE 6 tO OY SLC RE d E 6 1 ommo Enr T S ET 7 PLC Start up Rev 1 1 Page 1 0E Control Systems Start up Guide 1 Start Up Guide 1 1 Blender Power Up Wee 3 Va Connect power to the blender as per the See electrical wiring diagrams Please read the safety information in the introduction section for warnings and the maintenance Check that the operator display is showing the home screen as shown in Fig 1 The blender range is designed to allow easy Lb hr 718 37 operation for operators of all nationalities 1 2 Weight hopper Calibration Fig 1 Production Summary The most important factor regarding the blender is the weighing system It is very imp the weighing is correctly calibrated and is operating correctly Firstly ensure that there is nothing touching the load cell bracket Ensure that weigh hopper mounting bracket is not touching the frame of the blender PLC Start up Rev 1 1 Page 2 0E Control Systems Start up Guide Ensure that the load cell bracket is not touching the guards on the slide valves Touch BA e A keypad will pop up e Enter the supervisor password then return
22. ed on the top right of the screen Check that the LED on the solenoid is on and listen to hear if the solenoid valve activates If you can hear the solenoid valve activate but the valve does not open check the air pressure applied to the system If the solenoid valve does not activate check that the corresponding output from the PLC electronics module is operating If Touch Screen Check that power is applied to the panel check that the Ethernet connection Panel is not back to the plc is in place working If mixing motor is The mixing motor will timeout after 30 minutes if the blender does not not rotating cycle The motor will restart automatically when the level sensor becomes uncovered Ensure that mixing chamber door is firmly closed Check if contactor in the control cabinet is on Check that the power lead going to the motor is plugged in and pushed in fully t may be necessary to remove the mixing screw and check for objects jamming or screw misalignment PLC Start up Rev 1 1 Page 8 pm 55 TSM Batch Blender Control Systems User manual 1 User CT TE 2 Er ee DES e ve Te EE 2 1 2 ITU iei TE 3 1 2 1 Home screen Production Summary sse ee eee eee ee ee ee ee 3 kaa ASS VON SINC EE 4 1 3 Blender Operation checks sse eee eee 5 1 3 1 Breet ue T 6 1 02 Dender Tn cR Um 6 1 4 Etgen 7 1 4 1 Blender THOM e EE 8 To SVEN WN EE 9 1 5 1 Load Cell Calibration ess
23. ell is to observe the weight in on the screen Press down on the weigh hopper as shown below Then release the weigh hopper and check if the weight returns to the previous value For example if the weight used is 6 lbs then it should read 6000 5 when released If the reading sticks at 6100 for example then this indicates that there is a problem in the weighing and the previous checks should be done again This test verifies that nothing is restricting the operation of the load cell d BER E dal d MEL T A da Fn HE PLC Start up Rev 1 1 Page 4 Control Systems 1 3 Entering Set points Oi Toucn iial Enter the password the default password is 5 The recipe page is displayed as shown in Fig 3 SI Use Mati to move between recipes To enter the recipe name touch the Name section and enter the material name Then touch the component setpoint percentages for the individial components and enter the set points for each component Each time a keypad will pop up to allow the set points to be entered 1 3 1 Regrind entry optional Press E to select page two of the recipe entry This page allow the entry of a regrind component if regrind is being used For example if the regrind component is component 1 then 1 is entered for the Reg No Note that the regrind component set 96 is entered on recipe page 1 and the 96 is outside the 100 calculation U Now go back to the page 1 of the re
24. g 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 Verify that material is free to flow into the weigh hopper by opening the door of the blender remove the weight hopper and manually open the slide gate Verify that the valve is connected to compressed air supplying at least 6 0 bar 87 PSI Verify that the solenoid and relay is working correctly 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 material e Check the level of material in the mixing chamber If material is covering the level sensor even though it failed to detect material e Verify that the level sensor wire is securely connected to the correct terminal in the blender wiring Page 8 ae A TSM Control Systems Alarm message Possible cause Mixing motor Something has stopped the trip alarm mixing screw causing the current trip to trip Running The recipe has been component entered incorrectly percentage not egual to 100 Blender overfill One or more components alarm have over dispensed Rev 1 2 PLC Batch Blender 20 12 11 cabinet e Verify that the le
25. hen the current batch of material has been filled H Pressing this will start the blender operating again If the level sensor in the mixing chamber is uncovered the weigh hopper will be tared to zero and will fill the specified components in sequence EU This function is currently not being used at the moment WARNING The above options do not stop the mixing motor PLC Batch Blender User Guide Rev 1 1 Page 14 DTUEL TSM Control Systems Te len 2 Tr uico E m 2 1 1 1 How to use the lockout device 00nn6nntnennnenennanan ener 3 1 2 ROSONI IS m ER m TM 4 1 3 Maintenance check 4 VA Barre e e ee IRE 4 1 5 Cleaning blender during material change 4 1 6 Troubleshooting procedure nunn nennen nnne nnn 6 1 7 Determining the Cause of a roblem nnn 7 1 7 1 See dn E 7 1 8 Causes and resolution of alarms nn neuen nnnne enn na anna nan 8 1 9 Load Cell Checks and Calibration vanne nanennnan annan 10 1 10 Checking Component Fill Valve operaton eee eee ee eee eee 11 UE lt ie deo MERINO EE 17 2 some OUDDOED E 19 IS NIN AAA AO uu E E 20 Blender erer drawings E 20 Rev 1 2 PLC Batch Blender 20 12 11 Page 1 Control Systems 1 Maintenance 1 1 Safety Precautions Safety is a very important as regards working with the blender At no stage should safety interlocks be bypassed Power should always be removed from the blender when working on the electrics and air should be remove
26. if the material is not taken away from the blender The mixing screw will also be switched off if the mixing screw has been running without material for this time Number of Blends This is the number of components for which the blender has been configured PLC Batch Blender User Guide Rev 1 1 Page 11 pm 55 TSM Batch Blender Control Systems User manual Fill Retry 00 always This value specifies the number of fill retries the blender will perform if the blender does not get material into the weigh hopper on a particular component By setting this value to 00 the system will not proceed to the next component until it achieves its target weight for the current component If set to 1 the system will perform one fill retry and then proceed to the next component Similarly for two retries three retries etc Retry Recovery sometimes due to varying material feed rates the blender can have a different flow rate to the actual material flow rate This will cause the blender to continually retry If the system retries repeatedly for a number of cycles it is deemed that the flow rate is incorrect and the current flow will be accepted Top Up Reference Component This is the component that is used as the reference component for the top up e g component 4 may be used as the reference component Settle time This is the settling time in seconds that the system will wait after fill a component before the averaged weight is read
27. 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 Rev 1 2 PLC Batch Blender 20 12 11 Page 12 QE Control Systems Loadcell Weighing Accuracy Issues Frequently Howdolcleara Tare the blender for more a more detailed Tare alarm tare explanation see the quick start section page 1 2 Asked the blender e Ensure that mixing chamber door Questions hopper Is open Touch the button and enter the password Sa Calibrate Tare the hopper by touching This now becomes the zero reference point for the loadcell readings How dol know if Place a known weight e g 1kg 2 Ibs in the 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 e 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 Measurement IS Please check quick start guide FAQ section not functioning properly what should do am having problems with th Please check qui
28. ket to the load cell are tight Check the load cell connection in the blender cabinet to ensure that it is secured properly to the NBB electronics module Check the wiring of the load cell connector for short circuits loose wires or an unconnected shield wire Check that there are no granules pellets angle hair trapped around the load cell Blow out the area round the load cell with compressed air PLC Start up Rev 1 1 Page 7 2 Laf Start up Guide Problems with Fill The material fill slide valves for each component are operated using Valves solenoid valves located at the rear of the blender Each valve has an led so that you can see if the valve is on The solenoids for each valve are controlled by outputs located on the PLC The procedure to check the valve is Check the operator panel to ensure the software is opening the valve and that the blender is not in pause or stop mode front door open will be displayed on the main screen is it is paused Check the valve block LED S to see if the valve is switching on Use the manual switch on the valve block to check the operation of the valve Ensure that both of the air connectors are connected to each piston and that they are in the right orientation Ensure the pipes are not kinked If the valve does Check that air is applied to the blender The air supply should read at not operate least 6 0 bar on the pressure gauge Check that the pause stop icon H is not display
29. n will be displayed The cause of the alarm can be determined by going to the alarm screen PLC Batch Blender User Guide Rev 1 1 Page 2 el A User manual Batch Blender Cortal Systems User Guide 1 2 Menu Navigation The blender operator panel may be used to View production data Calibrate the blender Enter material recipes View Alarms View reports 1 2 1 Home screen Production Summary The production summary screen is shown below This page shows the set and actual component percentages the throughput and the menu buttons to allow menu navigation Set and actual Mode icon Shows if the blender is otopped Paused percentage for each component Alarm Icon Menu Icons PLC Batch Blender User Guide Rev 1 1 Page 3 al A TSM Batch Blender User manual Control Ce e The Touch Screen operator panel provides easy access to all parts of the SigmaBatch Blender menu structure 13409 PM Summary Mixer i Touch to enter the current recipe consisting of the component percentages and material names 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 lt is password protected so only authorised personnel can access any of the calibration sub menus LLIN From this menu it is possible to start pause or halt the blending process 1 2
30. nformation Solenoid source drivers in the plc Comp Status SetWgt Act Wat control the solenoid for each valve 1 Closed 5200 0 5234 48 i i 2 Closed 0 0000 0 00 GER the problem by following the 3 Gaua asi kis steps 1 Ensure the blender is not in stop pause mode This mode will be displayed on the top right corner of the home screen Dump Open Sensor Uncovered Hopper 1 pm the HH icon and EZB wo Sum Wat 65496 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 If the software is switching on the output but the slide valve is not opening then the next place to check is on the plc control module 3 On the 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 To check the slide valve remove power and air from the blender Empty the material hopper Open the front door of the blender and remove the hopper Manually move the slide valve to ensure it
31. o assist you e Check that power is supplied to the equipment e 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 e Please refer to the troubleshooting guide of this manual which may assist in solving the problems e Examine the instruction manual s carefully for associated equipment especially controls Each manual has its own troubleshooting guide to help you e Check that the equipment has been operated as described in this manual e Check that all connections comply completely with accompanying Page 19 M S TSM oy Control Systems 3 Appendix Blender electrical drawings Jore It Hii i il EI KI T n 1 apes N 3 Mil PU Les ae gt Rot 5 Ga e E E Sg x z ca me 5 s F MENS D e m K 16 Blender Contactor Box Rev 1 2 PLC Batch Blender Page 20 Bulls Eye Blender 1 Junction Box wiring Appendix Bypass uM CA VWebrotar OD Hd 53 o jamdiu IRL Wn SHd A3 DiisHd 3 OLiSHd A3 j pimesi ripe Li Skea sols 8101 Shea TUD SE 9112 mi n Jus el a m HI a 5 7 SSE Sun ip SOL ELL 53 20 gt g Eve ET E E LL cJ i 1160040 55 k TLADGLO 3o5 Bull Bank Flex Ll SH TU LS Hes Ha ag 181 TIL ewig LOL SHdA 9 L lz L it A8 II LUISA 28 tell Sk 28
32. power switch to On Check that the rotation of the Mixing is correct I E 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 Dump Flap Check whether stop pause icon is displayed on olide Gates are the top right of the home screen not operating e Ensure that the door of the mixing chamber is properly closed Check that the system is not in PAUSE mode Check that the plc is switched on and is operating Ensure that the factory air supply is connected TSM recommend air supply of 7 5 bar for optimum blender efficiency An 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 Rev 1 2 PLC Batch Blender 20 12 11 Frequently Asked Questions Page 15 DTUEL Control Systems Fill Valves have Please check quick start guide FAQ section problems with the fill valves If the slide Please check quick start guide FAQ section valves are not operating Other issues Accuracy e Sometimes a faulty load cell may affect accuracy Problems refer to page 2 in the Quick Start Guide to check the weight measurement Running the blender automatic test routine may identify the source of the blender inaccuracies TSM blenders incorporate and
33. r Started At Order Ended At Order Humber Semer 1 4314 22 2 LI 0 00 3 4552 14 0 00 Total 32557 10 Pleads sendin In order to use the order reports correctly the order totals 7 EE To reset the totals tick this box Reset Totals PLC Batch Blender User Guide Rev 1 1 Mil 1 I3 d nann NEM 1 v X E Page 7 QE User manual Batch Blender Control Systems 1 4 1 Blender information fal Blender Information Status SetWot Act Wot Press to blender information 1 Closed 5200 0 5175 54 screen his page shows the set and Closed 0 0000 0 00 actual weights for all components to be 3 Closed 12942 1281 65 viewed Also the open close status of the component can also be viewed The mixing chamber sensor and weigh hopper status can also be seen on this page Open Sensor Uncovered Hopper PLC Batch Blender User Guide Rev 1 1 Page 8 User manual QE Control Systems 1 5 System menu The system menu contains all the calibration and configuration options primarily used during initial setup and for 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 and the Engineering password to technical personnel The Password are shown on page 2 of this section of the manual
34. rm that has occurred or cleared the time at which it happened and it s current status To remove alarms touch the icon Note Alarm s clear every time the blender is powered off For the alarm description see the quick start section For more detailed information on what each Ge alarm message means and how to puc MEET e troubleshoot the alarm see the 11 20 15 AM 4243 2014 Blender Fill Alarm on Component 01 TROUBLESHOOTING section of this manual 11 20 41 AM 130 3 2011 Material Starvation Alarm ER PLC Batch Blender User Guide Rev 1 1 Page 6 User manual 1 4 Reports Press to view the reports menu The Reports Menu allows you to view various reports generated by the blender including the order report and the blender information page Order Press to see the order report This current report shows the production in the current 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 to set the order totals to zero i Mis Order Report The report shows all of the values for the previously completed order should be reset when starting a new recipe EM Batch Blender Control Systems O uer Huan G z Camp Hama Weight Lh 1 U E A U Tatal i lt ravio s Order Report Orde
35. trol options not covered in this User Guide e Verify that you have all instructional materials related to the TSM oigmaBatch blender its control systems and its components Additional details about troubleshooting and repairing specific components are in these manuals e 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 other equipment Word of Caution WARNING This machine should be adjusted and serviced only by qualified technical personnel only who are familiar with the construction and operation of this type of equipment 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 DANGER Voltage hazard Always disconnect and lock out the Rev 1 2 PLC Batch Blender 20 12 11 Page 6 ES TSM Control Systems 1 7 Determining the Cause of a Problem Blender alarms should initially indicate where the problem is 1 7 1 Blender alarms Most problems will trigger one of the blender alarms The blender includes alarm checks for 1 Individual components 2 Blender system alarms 33409 PM summary Mixer If an alarm o
36. vel sensor sensitivity setting is correct There is an adjustment pot on the sensor solution The current trip needs to be reset after checking that there is nothing stopping the mixing screw from turning It may be necessary to remove the screw Recheck the recipe This alarm should not occur if you are using the auto recipe entry setting Check that the max and min material flow rates are set correctly in the flows config Check that material is being fed to the blender consistently Page 9 ae A TSM Control Systems 1 9 Load Cell Checks and Calibration A malfunctioning load cell can lead to incorrect batch weights The problem may be caused by material trapped around the load cell housing a failure on the plc hardware electrical noise or a damaged load cell It is very important that the load cell is operating correctly To check the load cell e Power up the blender using the mains power switch located on the side of the blender Ensure that the power is removed from the mixing motor and the air has been removed Open the front door of the blender e 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 weigh hopper and load cell bracket position
37. ys closed for after it drops the material from the weigh hopper into the mixing chamber After the offline mixing time has elapsed the offline valve will open to release the material from the blender Sensitivity This option is currently unused Settles sampling period This should be setto 100 Vacuum System This option enables the vacuum system and should be enabled if a vacuum system is being controlled from the touch panel Max Batch Weight This is the limit for the top up mode For example if the total batch size is set to 5kgs the blender will not adjust component 1 in top up to exceed 5kgs Screen 3 SCH This allows the extent of the accuracy when Retry High weight 1000 00 the blender is retrying Retry Low Weight 20 00 Regrind High Weight Retry High Percent 90 0 Above this weight the high percentage is RE ae AENEAN 80 0 used Retry Low Percent 70 0 Regrind Low Weight Below this weight the low percentage is used Between the high and the low weight the Retry Med Percent is used SHUTDOWN APPLICATION SHUTDOWN Touch as shown to set the network settings 00210 PLC Batch Blender User Guide Rev 1 1 Page 13 TEM Batch Blender User manual Control Systems SUMMA Mixer 1 6 Pause and Restart Mode Mode Press LEN to select the mode page na Teng The three options in the Mode menu they can be used to When this button is pressed the an blender is paused and willl stop operation w
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