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Sterling Blender A0567659 User's Manual

1. A stroke limiter included can be installed on the metering gates to limit their travel This device decreases the stroke of the gate and reduces the metering orifice of the valve The unique diamond gate provides a square opening at any stroke length providing more consistent flow from smaller valve openings than conventional slide gates This stroke limiter may be necessary to accurately meter low percentage ingredients The air cylinders operating the slide gate are rugged stainless steel cylinders designed for industrial use 7 DIAMOND GATE OPEN The unique Sterling diamond gate provides a constant aspect opening that remains square regardless of the stroke length of the cylinder This design provides a wider namoro cate 12 coseo M cross sectional opening when approaching a closed position and provides better flow of plastic pellets out of D the opening DIAMOND GATE 3 4 CLOSED i DIAMOND GATE CLOSED WARNING Slide gates create a pinch point hazard Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning any blender including all SGB Series models Failure to do so may result in serious injury gt gt J SGB Batch Blender with Mitsubishi Controller Page 15 of 118 Sy Important Page 16 of 118 Each of the diamond gate air cylinders is actuated by a solenoid valve which are controlled by the blender When the solen
2. REPORT SETUP Blender Number SCALE CALIBRATION PERFORMA SCALE CALIBRATION ON ALL MANUFACTURED UNITS DIRECT SCALE LOG THESE VALUES AFTER THE SCALE CAL WITH THE ORDER READOUT INFORMATION FEEDER CALIBRATION EME 0 25 0 25 MIXER AND DUMP SETUP Hi ee a bee i ne A ez SGB Batch Blender with Mitsubishi Page 112 of 118 Controller a e eee e eee Continuous Timed Mixing TIMED USER PASSWORD User Password 5413 Maintenance Password 3145348 SGB BLENDER CONFIGURATION PARAMETERS Cont d Model Number Type SGB 5000 ALARM SETUP Hop1 Continue Stop on Hop2 Continue Stop on Hop3 Continue Stop on Hop4 Continue Stop on STOP Hop5 Continue Stop on Hop6 Continue Stop on Hop1 Alarm No Alarm on Hop2 Alarm No Alarm on Hop3 Alarm No Alarm on Hop4 Alarm No Alarm on ALARM Hop5 Alarm No Alarm on Hop6 Alarm No Alarm on O TJO JJO TJO TO JO TJO T O T O TjO IjO TJO SF OlE SOS FOIE OIE FOIE Ole FOIE h h h h h o BO ajo Afo W O NJo gt jo Sjo Glo Ajo Wlo Njo g 9 9 S SIS SLS SLS TNS DSS RS SSS vjr Xj lo Yio Yjo Aja Sjo 5 L Sj S S o 3 9 3 9 3 9 3 9 3 9 Z Slo Slo S Slo Sjo 3 3 3 3 3 3 3 3 3 3 3 3 D ZIS ZIS ZIS ZIS ZIY Slo SIS Sim SIS SJS o g gL gL sil L SL EIL pL L yL yL sL ADVANCED WEIGHT OPTIONS JR E E Ig JE Above batch size for max weight J 3 D A D 3 oO gt O Dd D D S D gt D S batch du
3. Service Notes Page 116 of 118 gt SGB Batch Blender with Mitsubishi Controller w Service Notes N SGB Batch Blender with Mitsubishi Controller Page 117 of 118 wy Page 118 of 118 SGB Batch Blender with Mitsubishi Controller lt
4. Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts of electrical apparatus electrical component enclosures and the blender frame are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes which apply When you have completed the repair or maintenance procedure check your work remove your tools rigging and handling equipment Do not restore power to the blender until all persons are clear of the area Start and run the blender until you are sure all parts are functioning correctly BEFORE you turn the blender over to the operator for production verify all guards and safety devices are in place and functioning properly 2 8 Safety 2 8 1 Description and Objectives This section includes information on safety devices and procedures that are inherent to the SGB blending system This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describ
5. All personnel operating the SGB blending system should read this section of the manual before operating the blending system 5 8 11 General Operation The general operation of the SGB blending system is as follows Once the system is properly installed and set up the system will be ready for operation Please see the Installation and Setup chapter in this manual for further information Once the SGB system is powered on the unit will display the recipe screen the recipe format should be in Quick Set mode Pressing the highlighted box next to the feeder number the operator can enter a valid recipe or use a previously stored recipe from the recipe book 5 8 12 Feeder Clean Out Any feeder in the SGB blending system can be emptied and refilled with a different material To do a feeder clean out the operator has to press the Clean Out icon key from the recipe screen the first screen that appears on power up N SGB Batch Blender with Mitsubishi Controller Page 65 of 118 wT Important Page 66 of 118 This screen will allow you to Open or Close the Feeder Weigh Hopper Mixer Knife Gate Empty the Entire Blender Start or Stop the Mixer Motor Test the Alarm Output Find out the Mixer Proximity Status and monitor the Current Hopper Weight Te Empty Entire Open or Close CSSARE Blender Fe
6. aO e HEHH HH TOTAL HHH HHH HH Go to Recipe Page Clear the inventory totals eens i Material umber of Batches Usage Rate This display indicates the amount of material in pounds that has been used by each feeder of the recipe It is important to note that the weights are rounded off to the closest pound On minor ingredients several cycles may have to occur to show an inventory number In addition to showing the amount of material that has been used for each feeder this screen is also a summary display that shows the total inventory the time for the last batch and the average rate of the blender If the blender is run in Percentage Mode instead of Quick Set during operation the Percentage Mode will use the blender inventory numbers shown on the Inventory screen to calculate the percentages for each ingredient It is important to zero the inventories when a recipe is changed to have this screen accurately reflect the current percentages of the recipe in process Note Blender inventories must be cleared when the current recipe is started to show accurate percentages for the current recipe To clear inventories press the Clear Inventory key on the Inventory screen 5 8 14 Recipe Menu Note Refer to the menu structure in section 5 4 for more information The SGB System contains several operator friendly recipe menus This section of the manual lists these recipe menus e Reci
7. as close to the center position between the load cells as possible Important Use care when replacing the weigh hopper since the load cells are delicate weighing instruments and can be easily damaged Do not use force to push in the weigh hopper If it is positioned properly it will slide in very easily Load cells if damaged will have to be sent back to the manufacturer for testing and evaluation LOCATING TABS LOAD CELL LOAD CELL AIR CYLINDER DISCHARGE VALVE N SGB Batch Blender with Mitsubishi Controller Page 17 of 118 wT 1 11 4 Weigh Hopper Discharge Valve The weigh hopper discharge valve holds the material until it is dumped into the mixing section The cylinder is actuated by a solenoid in the valve stack on the rear of the blender In looking at the pneumatic circuit you can see that the air regulator controls the flow of air to the valve stack When the weigh hopper discharge cylinder solenoid valve is not electrically energized it will provide air pressure to the air cylinder and hold the shaft in an extended position holding the dump valve closed When the air cylinder is actuated the air pressure to the dump valve will be removed causing it to open The air cylinder on the weigh hopper includes a spring return to allow the cylinder to retract in the absence of air pressure on the cylinder This will cause the dump valve to open CAUTION The pneumatic system used on the SGB like all pneumatic system
8. 19 20 21 22 23 24 25 26 Da 28 29 30 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Special installation requirements Clean dry compressed air 1 cfm 60 psi 1 7 m hr 4 14 bar Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 120 1 60 or 220 1 50 60 Verify on serial number tag Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a neutral power connection Over current protection is supplied in the blender but additional protection should be supplied by the user The plug on the power cord serves as the electrical disconnect device Unit is not equipped with three phase motors N A Blender is not equipped with local lighting Functional identification Blender is equipped with a CE mark Blender is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit On
9. 8 20 Controller Features Page 76 of 118 Press to Access the F940 Config 5 8 20 1 Display Time and Date The display Time and Date item in the upper right corner of the F940 Config menu is used to verify the current time and date information 5 8 20 2 Setting Date amp Time The Set Date amp Time feature is located in the Panel View Config menu of the Setup Screen This feature allows the operator to set the SGB s internal time clock and date The clock data must be entered in the traditional Hours Minutes and seconds The date must be entered in Years Months and Days All values in this screen can be entered by pressing on the related button and choosing the correct number Go back to Setup Directory 940 Config Scree F940 w PLE Blender Version H H 2450 F340 Date amp Time PLO Hour CThiS i5 automatically set at midnight and noon bY the F340 HH PN SGB Batch Blender with Mitsubishi Controller 5 9 Stroke Limiters for Metering Gates Stroke limiters are supplied on components 1 through 4 with all SGB blenders to allow standard metering gates to meter small amounts of low percentage additive materials Generally the stroke limiter Item 30 is not required on major ingredients usually number 1 and 3 and should be removed If they are left in place throughput of the blender will be reduced To install the stroke limiter drop it int
10. 8 5 Mixer Options Press the Timed Continuous Mixing key In the top right hand corner when in Mixer and Dump Setup screen to set the following options Timed Mixing Option This mode of operation turns the mixer on only during dumping and during the re mix time set into the control to jog the mixer during high level mixer operation Continuous Mixing Option This mode of operation turns the mixer on after initial startup and will continue to run continuously unless the remix time is set to jog the mixer during high level mixer operation This option is used for sticky materials that tend to bridge and block off the mixer discharge to the processing machine 5 8 6 Weigh Hopper Dump Time The weigh hopper dump time is the amount of time the weigh hopper s dump valve remains open to allow weighed material to exit the hopper and enter the mixer To view and change the current weigh hopper dump time settings enter the Setup menu and select the Mixer and Dump Setup screen Press the field next to Dump Time to set the operation of the Dump Valve The dump timer on the dump valve has a default time of eight 8 seconds This time can be adjusted to optimize the blender cycle time The timer should be set to close the dump valve shortly after the material has totally dumped from the weigh hopper This time can vary due to material flow characteristics and the size of the batch that is programmed into the blender contr
11. Blender version Main 1 1 PLC Version Copyr ight ray The Operator Interface has been lacked HHH H 2001 Blender Stopped 3s EN Book Next I O 1 Clear Inventory Average Batch Pounds Used Pa ES a HHH HH atl 2 HHHHHHHH HHH rita ino AHHH HHH HEERE lt HARA HH S HHHHHHHH HHH e HHHHHHHH HHH To Te HHH HHH Ox Next Process Rate LbsvHr HHH tetteti Wits tits HOPPER 1 OUT OF MATERIAL i EEA StErase Feci pe gt HH za be Base All Be REF ipnnnnnHH PEN atch _ Size_ t Inventory Shutdown tinting UOO OH E E HHH HH F F F a fipa E FE EE 4 hippi F Load ammm ammm ammm AHHH HH ees Oe eT Ones E 4 Done N SGB Batch Blender with Mitsubishi Controller lt i gt Sy Page 21 of 118 Note The touch screen panel display on your unit may be slightly different than shown UJ aw iy ii ev cuits Page 22 of 118 SGB Batch Blender with Mitsubishi Controller 1 12 Pneumatic Slide Gate Below Mixer Optional SS wT The SGB blending system can be equipped with an optional pneumatic slide gate below the mixing chamber The gate is used in applications when the blender is mounted above a large hopper or for gaylord filling etc This gate holds the material in the mixing section to ensure that it is properly mixed Control of the mixer func
12. Description Model SGB 2500 SGB 4000 amp SGB 5000 PartNo Description O A0556548 Mixer High Level Sensor 53266 Slidegate Air Cylinder 5 stroke SGB4000 only 35479 Slidegate Air Cylinder 6 stroke SGB5000 only 0801100 la Page 90 of 118 lt gt SGB Batch Blender with Mitsubishi Controller A0565882 Calex Module 0569702 A0569708 SGB Graphics Panel A0542200 1 5 Amp Fuse A0542207 3 0 Amp Fuse A0569108 Calibration Weight 25 Ibs 9 2 Model SGB Blender System Component Description This section describes the various components of the blending system The SGB blending system is made up of the following components e Ingredient Supply Hoppers e Ingredient Weigh Hopper e Ingredient Metering Slide Gate Assemblies e Rotary Mixer e Computer Control Panel 9 2 1 Overview Component Identification and Location This section will familiarize the reader with the components of the SGB blending system After reading this section the reader will be able to e Identify the individual common components of the SGB blending system Typical Model SGB Assembly Overview N SGB Batch Blender with Mitsubishi Controller Page 91 of 118 wT 9 2 2 Typical Mixer Section Front Typical Opti Mixer Front Assembly Detail Lo Page 92 of 118 lt gt SGB Batch Blender with Mitsubishi Controller R N J i AA Xe A tie lt N mes ee NX Ss va N l 7 d T 4 ae re A CAT a e
13. Page 50 of 118 SGB Batch Blender with Mitsubishi Controller 5 4 SGB Series Control System Menu Structure Recipe Page Recipe Book Page a Start Save the running recipe to the gt Change Recipe Values by book touching the number you wish to Delete a stored recipe change a Load a stored recipe Touch Accept New Recipe Erase all stored recipes button after you ve made the Modify the product ID for a ae changes stored recipe tart or stop the blender by ina touching the Push to Start or Return to the Recipe page Stop button Access Recipe Book Page Access Clean Out Page Clean Out Page Access Inventory Page Empty the blender hopper s Access Setup Page Manually Operate the mixer weigh hopper dump gate and the slide gate below the mixer View and test all inputs and outputs on the blender Return to the Recipe Page Inventory Page View the accumulated inventories View batch time View blender s maximum capacity View the average process rate Return to the Recipe Page Login Logout Setup Page gt Login by going to Inventory page touch Login then enter your password Touch the Sterling logo to access setup N SGB Batch Blender with Mitsubishi Controller Recipe Format Percentage Parts or Quick Set Batch Size Inventory Shutdown Batch ready mode Auto start mode Report Setup Blender Number Auto c
14. material Enter the recipe menu on the LCD panel by turning on the Mitsubishi controller It will automatically default to this screen and enter the blend recipe desired following the steps listed below e Touch the box labeled 1 6 that shows the value you want to change e Enter in the new value 0 to 999 99 and hit the enter button arrow e After you have entered the new values for all hoppers 1 6 then push the Accept New Recipe button and the recipe will be entered The blender monitors the operator s entries and determines if the recipe entered is valid before allowing the operator to accept the new recipe If there is an error such as the recipe does not add up to 100 and the blender is in Percentage Mode then a message is shown on the Recipe screen to alert the operator of the problem The Accept New Recipe button is only shown if the recipe is valid and different from what is currently running on the blender N SGB Batch Blender with Mitsubishi Controller Page 47 of 118 wT Recipes can also be changed while the blender is running The new accepted recipe is entered at the beginning of the next batch This allows the operator to modify the new recipe without affecting the blender until they hit the Accept New Recipe button OR 4 The operator can load a previously stored recipe from the Recipe Book The Recipe book also allows the operators to save the current running recipe This can be done b
15. off air to the blender circuit by deactivating the master air valve Then unplug the quick disconnect from the air supply hose to the blender to further ensure that no air pressure is supplied to the blender WARNING e Always unplug the main power cord prior to performing any operations inside any access areas of e Always disconnect the air supply to the blender fax Page 56 of 118 gt SGB Batch Blender with Mitsubishi Controller the blender where there are moving parts 4 Remove the weigh hopper by unplugging the air line disconnect fitting holding the dump valve closed lifting the hopper to clear the load cell brackets and gently pulling the weigh hopper out of the blender Important To reduce the chance for damage to delicate load cells use care when lifting the weigh hopper off load cell locating tabs and when reinstalling the weigh hopper on load cell brackets 5 If you want to catch the color use a small plastic pail or chute to collect the material from the slide gate assembly Reach up inside the blender to the color slide gate and push it open At this point there should be no air pressure on the blender and the slide gate should move easily Drain the color out in the bucket Blend and Reclaim normally provides a JIT Just in time approach to the minor ingredients so that a minimum amount of material is held in the blender so that color changes can be made easily 6 If any other ingredients need to
16. panel with 8 cable Target vs actual set point verification Inventory accumulation for all ingredients Audible and visual alarms Auxiliary alarm contact 50 recipe storage book Three 3 types of recipe entry procedures available v Quick Set up to 6 component recipe entry Color and additives are metered as a percentage of the virgin material y Percentage mode recipe entry Ingredients are metered as a percentage of the overall batch v Parts mode recipe entry i e 500 1 Ingredients are metered as a ratio to each other within the batch e Full control diagnostics e RS 422 communications ports SGB Batch Blender with Mitsubishi Controller Page 11 of 118 1 10 SGB E Series Specifications O75 GH 152 76 Weigh hopper capacity ft I 0 65 18 1 4 39 sen 200 75 4 ren zao Maximum blending rate approx Ibs hr kg hr 700 318 1500 680 3500 1590 4000 1820 5000 2270 Weight of machine approx Ibs kg 200 91 600 275 Shipping weight approx Ibs kg 850 390 Based on 78 virgin 20 regrind and 2 Color Note SGB features and specifications are subject to change without notice PN Page 12 of 118 SGB Batch Blender with Mitsubishi Controller 1 11 Model SGB Blender System Component Description This section describes the various components of the blending system The SGB blending system is made up of the following components 1 11 1 Material Supply Hoppers 1 11 2 Slid
17. to hold several recipes in the memory of the blending system The SGB has provided for this by incorporating Sterling s recipe book software The recipe book is capable of holding 50 different recipes These may be stored and recalled by number During this section of the manual the operator may wish to revert to the Menu Tree Diagram on page 51 of this manual It is important to note that the recipe book only stores and recalls recipes The blender will operate on the current recipe only so a recipe must be recalled from the book to the current recipe for it to be active Each recipe stored in the recipe book may be displayed and or modified Only the current recipe will be blended N SGB Batch Blender with Mitsubishi Controller Page 73 of 118 wT Always verify that the Current Recipe is showing what you want to run and that the correct recipe has been downloaded from the book The recipe book section contains the following Items e Save Running Recipe to the Book e Load a Stored Recipe from the Book e Display a Stored Recipe e Erase One Recipe or the Entire Recipe Book Erase One Select a Recipel gt HH Ra ateras Stored Recipe it Base All Stored Recipe REFHE tenant mh Erase Entire atch Size ttt Book Stored Recipe Inventory Shutdown ttttntinit Peta nai a 2 Load Stored _ _ Recipe EHHH H E p 4 Be E Load uE HH E t Go to z PUN pene Reci
18. workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not express
19. 1 3 4 le Press tu Hop Wt Start or Stop Press Press OPEN WEIGHT Current Hopper OFEN OFEN HOFFER HHH ei Mixer Motor SF Presa ta Lbs Weight START MIXER Open or Close 8 AE net Mee Knife eS Go back to Setup Gate Directory Low Level Mixer Proximity Proximity Status Status R Page 58 of 118 SGB Batch Blender with Mitsubishi Controller 5 8 2 Weigh Hopper Load Cell Calibration on blenders equipped with an OptiMix mixer Enter the Setup menu as described previously See Section 5 3 for menu tree The factory pre calibrates the weigh hopper on the SGB blenders Button 3 on the Setup Menu is Calibration Press it to enter the screen Shown below which will prompt you to enter the Calibration area Press the button marked Scale Calibration to enter the scale calibration menu Scale Calibration a ete to Setup irect Scale Readou rectory Feeder Calibration 1 Once in Scale Calibration enter in the scale calibration weight value stamped on the side of the weight 2 The controller will prompt you to remove the weight hopper and press OK 3 After touching OK the controller will display PLEASE WAIT 4 Next the controller will ask you to hang the calibration weight on the right loadcell bracket loadcell A and press OK 5 The controller will ask you to hang the calibration weight on the left loadcell bracket loadcell B and press OK 6 Finally the
20. 3 then touch the Sterling logo to access setup 2 Touch Calibration and then Direct Scale Readout 3 Remove the weigh hopper 4 Locate the weight display for each of the two load cells directly below Current Bits Write down the displayed value 5 Add the calibration weight to each load cell mounting bracket and write down the value displayed in weight as in step 4 6 Subtract the values recorded in step 4 from step 5 This is the measured weight If the measured weight is within a 0 003 pounds of the weight stamped on the calibration weight then you are within spec If not follow the steps above to calibrate the blender If your blender is frequently out of calibration verify the operator is being cautious removing the weigh hopper for clean out 7 Press Done until you have reached the Recipe screen 8 Anything in the Diagnostics Menu that is not covered here is in the Detailed Controller Setup Section 5 6 Controller Mode Setup Setting up a recipe 1 Login by touching login from the Inventory Page and enter 5413 then touch the Sterling Logo to access setup 2 Press Recipe Format and toggle through the EZ Percentage or Parts Modes 3 While in the Recipe Format screen the following areas will need to be configured Batch Size This allows the operator to change the size of the batch to be made A value will need to be entered between 0 5 to 199 9 This
21. ANT emphasizes areas where equipment damage NOTE If you believe that your equipment has a defect which could cause injury you should immediately discontinue its use and inform Sterling at our address listed in this manual The principle factors which can result in injury are 1 Failure to follow proper operating and clean out procedures i e lockout tagout 2 Failure to maintain a clean and safe working environment 2 5 General Responsibility NO MATTER WHO YOU ARE Safety is important Owners operators and maintenance personnel must realize that every day safety is a vital aspect of their jobs If your main concern is loss of productivity remember this Production is always affected in a negative way following an accident The following are some of the reasons which can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e Down time An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be fax Page 26 of 118 SGB Batch Blender with Mitsubishi Controller 2 6 continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for
22. SGB Series Gravimetric Batch Blenders With Mitsubishi Controller Standard amp CE Models Operation Installation and Service Manual Sterling 2900 S 160th Street New Berlin WI 53151 Tel 262 641 8600 Fax 262 641 8653 www sterlco com Part No A0567659 Bulletin No SM1 605M 4113 03 Model Serial Write down your Blender serial numbers here for future reference Sterling is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling 2003 All rights reserved Revision NEW Part No A0567659 Bulletin No SM1 605M Page 2 of 118 ke SGB Batch Blender with Mitsubishi Controller Table of Contents Table Ol G ONIGNS siesta het Aer go it teed E hed EEE 3 Safety Considerations ei csv ccentedns sveceet cee NG nse ieecuamas ecesteb ad Mie Blade Netdsacaah wes 5 Annex B Information i ieiccntc oat rdcrdssaetadscns sdareesdiseaasatdeartalmertatsaadwes 7 dr General Informatio Msisi inina lilt Re tlre 8 WA APE CAUGUO Mas Gus E A T E Geriues 8 1 2 EQuipment FUunClon i nenecdnpnnnen Giaetapn ete HES 8 TS ACCESSOS S vat ae e e A e Ea a e EA A e aae EEE 8 1 4 Customer ServiCe c ccccccceeeecceceeeeeseeeeeeeeceeeeeaeeseeeeeeeeeeeeeaaaeees 8 1 5 Necessary Documents 2 220e teessheetee sete eteee
23. Set it to Timed Mixing Check the value of the mixer timer setting Check the value of the dump delay timer Check the mixer motor fuse This is located in the control panel on the SSR for the mixer motor If the unit has two 2 power inlets with a separate power inlet for the mix motor the overload fuse will be located in the rear junction box on the blender frame Check the power source to the blender Check the load cell in diagnostics under direct scale readout Place a calibration weight on the weigh hopper determine if the weight corresponds Check the load cells to make sure that a pellet has not jammed under a load cell Check the load cell connections to the control panel Check the power supply voltage and readjust as necessary as described earlier Check the memory battery voltage on the CPU board If the battery is dead the blender forgets settings when the power is off Replace it with a new battery Order a spare CPU board send the replaced one back to the factory to have a new battery holder and battery installed If this is done in the field the controller warranty will be voided Out of Material Alarm is Go to the Manual Control Page and check to see if Hop Low equals 1 displayed but there is If it does then adjust the low level prox until the value reads 0 material in the hopper Ensure that the material hopper is properly vented If the vacuum receiver is leaky then this will cause the problem
24. The Controller will stay on this screen for about 4 seconds then enter the Recipe Screen Next Screen in sequence The software versions are also available on the F940 Configuration Screen N SGB Batch Blender with Mitsubishi Controller lt i gt wT Page 45 of 118 4 The screen shown below allows the operator to control the blender The blender can be started or stopped and the recipe values can be changed Other data shown on this screen consists of the mixer status recipe status and feeder type data The Recipe Screen should startup in the Quick Set mode If so enter a valid recipe New Recipe Recipe Entry Mode Input k agnose Okean out Mixer Status Feeder Type Indicator Go To Inventory Screen Go To Recipe Book Start Stop Blender Immediately Stop Blender 4 i Accept New Recipe If not the blender can be reconfigured for Quick Set Percent or Parts by entering the Setup menu and pressing the Recipe Format key Then select the mode following the key prompt on the screen To access the Setup Menu to change the Recipe Mode and other controller features refer to the Appendix in Section 12 of this manual 5 The operator can startup the blender by selecting the button that says Push to Start or Stop startup on the left side of the Recipe Screen depending on whether the blender is currently running or is stopped Simply touch the button to either st
25. To test this fill up the hopper and turn the loader off to prevent leaking If this isn t the problem then increase the Out of Material Retry Limit found under Feed Algorithm Options see manual I m not getting Out of Check the Alarm Flags amp Feeder Setup to see if the feeder is configured Material Alarms to give you an alarm Calibration Weight Clean out the hopper and retest If this doesn t fix the problem then Exceeded perform a scale calibration Also check to sure that the Dump Time is not set extremely low If all else fails check the value set for the Max Empty Weight This might need to be increased The feeder calibration First check that the displayed actual dispensed weight is accurate If this values are moving too is OK then check to see if the hopper is properly vented To do this fill much hopper and turn off the loader and retest can t calibrate the Scale This is caused by the difference in bits not being large enough Using the without an error message Direct Scale Readout examine current loadcell bits with and without the calibration weight If the bits do not change significantly then check for pellets jamming the loadcells and check the loadcell circuit You might have a bad loadcell can t calibrate the feeder Do other feeders calibrate correctly Is the feeder I m trying to calibrate a without an error message large gate If these are true then lower the Batch for Feeder Ca
26. a means to automatically stop the blending system when the blended material has reached a preset total blended weight This is known as Inventory Shutdown la Page 72 of 118 SGB Batch Blender with Mitsubishi Controller When the Inventory Shutdown value is reached the blender will finish the current batch of material It will then stop and display to the operator that the inventory value has been reached Additionally it will flash an alarm and wait for operator attention An example of this screen is shown below Touch if you don t aa want to make inventa shutdown amoun and has been stopped another batch Touch to make iz another box of Restart Stop material Blender Blende To enable this feature simply enter a desired shutdown weight value from 1 to 999999999 into the Inventory Shutdown display line of the Recipe Format screen under the Setup menu This feature can be configured while the blender is making a batch If the Inventory Shutdown is changed then you will need to touch Accept New Recipe on the Recipe screen before the change can take place This allows stored recipes with different Inventory Shutdown settings to easily be loaded without the operator having to reconfigure the blender every time they want to load a stored recipe To disable this feature simply enter a zero 0 value 5 8 19 Recipe Book Storage Menus In many applications it is favorable
27. and Installation manuals for supplied options and accessories System Capabilities Blending systems are as varied as the applications that they service This equipment is intended to blend the materials s specified at the time of purchase at specific rates 1 7 Equipment Covered by this Manual SS wT SGB Blenders e SGB 450 SGB 900 SGB 2500 SGB 4000 SGB 5000 SGB Batch Blender with Mitsubishi Controller Page 9 of 118 1 8 SGB Series Weigh Blender Mechanical Features Page 10 of 118 SGB Slide Gate Blender Efficient Opti Mixer and HC mixer designs promote homogeneity Exclusive diamond design slide gate metering assemblies meter a large range for free flowing pellet materials Slide gate stroke limiting restrictors provided for accurate metering of minor ingredients Electro polished 304 SS stainless steel weighing and blending components Precision 1 10 span accurate cantilever load cell weighing system Removable stainless steel weigh hopper Removable stainless steel mixer agitator and mixer wrap Opti Mixer only Mild steel material supply hoppers with clean out doors and material drains Compressed air hose with nozzle for clean out Safety interlocked system shuts off compressed air and electricity if mixer is opened SGB Batch Blender with Mitsubishi Controller 1 9 SGB Series Weigh Blender with Mitsubishi Touch Screen Control Features LCD touch screen interface display operator control
28. and union or non union installations 10 2 Returned Material Policy 10 2 1 Credit Returns 1 Prior to the return of any material authorization must be given by Sterling A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from Sterling returned is subject to 15 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale 10 2 2 Warranty Returns Page 100 of 118 Controller 1 Prior to the return of any material authorization must be given by Sterling A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at Sterling s discretion If the item is found to be defective in materials or workmanship and it was manufactured by Sterling purchased components are covered under their specific warranty terms gt gt SGB Batch Blender with Mitsubishi 10 3 Warranty Sterling warrants all equipment manufactured by it to be free from defects in
29. art or stop the blender If the operator selects Stop Blender then the current batch in progress is first finished and then the blender will stop making new batches To immediately stop the blender the operator can touch Abort Current Batch This will cause the blender to stop making the current batch immediately Obviously if the blender is stopped in this method then the current batch will not be completed properly la Page 46 of 118 SGB Batch Blender with Mitsubishi Controller Operation 5 1 SGB Blender Sequence of Operation 1 Blender is started by turning system on or material dropping below level switch in mix chamber Metering gates are opened to meter material into the weigh hopper in the programmed order Each component is weighed then the batch is dumped into the mix chamber provided the mixer High level switch is not covered The material is mixed in the mix chamber and flows into the processing machine The optional slide gate below the mixer may control the flow of material to the molding machine or extruder 5 2 Quick Start Procedure 1 Calibrate the weigh hopper before running the blender This will improve inventory accuracy Ensure that all ingredient supply hoppers to be used are filled with material Virgin material should be loaded into hopper 1 and regrind into hopper 3 Note Hopper 3 is equipped with an oversized square gate to assist in the feeding of the regrind
30. ased on a percentage of the virgin weight This is useful because the percentage of regrind can be changed without affecting the ratio of color or additive to the virgin weight Each percentage can be up to 100 but not greater The virgin percentage is automatically calculated by LX Page 48 of 118 gt SGB Batch Blender with Mitsubishi Controller the blender and the operator is not required to enter it The ingredient names selected will be displayed on the run mode display so the operator will Know what material is being blended Important The 1 hopper NAT Virgin Material recipe ingredient will not be shown on the recipe setup menu ADD Additive designations will weigh the ingredient as a percentage of natural material only RGD Regrind designations will weigh the ingredient as a percentage of the total batch Virgin material must be loaded into hopper 1 and regrind into hopper 3 5 3 2 Percentage Mode Most common in extrusion and blow molding Extrusion processing often requires recipes in percentage format especially if regrind is not involved i e blown or cast film In this mode operators enter in values for each hopper up to 100 The total of all the hoppers must equal 100 If they don t an error message appears on the Recipe screen and prevents the recipe from being accepted All hoppers are a percentage of the total batch size Important All ingredients are weighed as a percenta
31. aterial out of the blender with your hands while it is running e Before you start the blender check the following Remove all tools from the blender e Be sure no objects tools nuts bolts clamps bars are laying in the metering or mixing area e f your blender has been inoperative or unattended check all settings N SGB Batch Blender with Mitsubishi Controller Page 27 of 118 before starting the unit e At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly e Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment e When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting e Report the following occurrences IMMEDIATELY e unsafe operation or condition unusual blender action e leakage improper maintenance e NEVER stand or sit where you could slip or stumble into the blender while working on it e DO NOT wear loose clothing or jewelry which can be caught while working on a blender In addition cover or tie back long hair e Clean the blender and surrounding area DAILY and inspect the machine for loose missing or broken
32. batching system The blender will weigh a preprogrammed batch of material each cycle This batch size is determined by the blender s weigh hopper size the current recipe and the bulk density of the ingredients Because the blending systems must handle a wide variety of materials with varying bulk densities the actual amount of weight of material the weigh hopper will hold can vary dramatically from application to application The weigh hopper size selected should be one that approaches the maximum capacity of the load cells without over filling the weigh hopper During the initial setup of each blender the weigh hopper size setting should be checked to ensure that the weigh hopper is not overfilling due to a large percentage of light weight regrind etc The batch size will vary from model to model The bulk density of the material being blended will also affect the batch size Important If running a high percentage of lighter density regrind Set the batch size so that the mixer does not overfill preventing the weigh hopper from fully dumping when operating in Batch Ready Mode 5 8 18 Inventory Shutdown In many applications the user of the SGB System produces large runs of blended material on the same recipe during production An example may be a 40 000 Ib run of a certain specification plastic extrusion Others may wish to fill a 1 000 Ib gaylord box in a central blending application In either case Sterling has provided
33. be changed for the next recipe simply drain the larger hoppers with the drain tubes provided on the side of the hoppers When the material level is below the drain tube open the slide gate manually to dump the rest of the material If you wish to speed the emptying process material can be manually drained out of the slide gate assembly into a dump chute or bucket while draining from the drain tube 7 Using a vacuum cleaner or air hose clean out all the hoppers that have been emptied Always start at the uppermost part of the blender and work downward to prevent dust and pellets from falling into an already cleaned area oe Clean the weigh hopper and mixer assemblies on the blender using a vacuum cleaner The mixer agitator is removable for cleaning if desired Reinstall any metering units that were removed from the blender during clean out 10 Reinstall the weigh hopper using care to center the hopper on the load cells on the weigh hopper bracket 11 Load the blender with new material 12 Restart the unit with the new recipe WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning any Sterling product including all SGB Series blending systems Failure to do so may result in serious injury or death aay J SGB Batch Blender with Mitsubishi Controller Page 57 of 118 Sy 5 8 Additional Operation Features 5 8 1 Display Descriptio
34. can also be changed while making a batch without affecting the current running batch If the size is changed then you will need to touch Accept New Recipe on the Recipe screen before the change takes place This feature allows stored recipes with different batch sizes to easily be loaded without the operator having to reconfigure the blender every time they want to load a stored recipe la Page 54 of 118 SGB Batch Blender with Mitsubishi Controller Inventory Shutdown Touch to make another box of material Batch Ready Mode AutoStart Feature This feature allows the blender to make a certain amount of material at a time If this feature is set to 0 then the feature will be disabled If this option is used the blender will make the set amount of material and will then shutdown and wait for the operator to restart the blender This feature is useful when filling gaylord boxes You no longer have to be troubled by a proximity switch that hangs in the box to sense when it is full The following screen is shown when the blender reaches the Inventory Shutdown weight The blender has reached the ROR oy shutdown amoun t and has been stopped Touch if you don t want to make another batch 1 Restart Stop Blender Blender The Inventory Shutdown can also be configured while the blender is making a batch If the Inventory Shutdown is changed then you need to touc
35. cause an overfill condition on the next few cycles Check the load cell connections to the panel Material tends to separate Check the mix timer setting This problem is normally due to over mixing in the mixing chamber See the mix timer section in the setup chapter Reduce the time until the problem is corrected Check the mixer drive to ensure that the agitator is turning properly Check the high level switch in the mixer to lower the level slightly Material sticks to the Increase the Dump Cycles setting in Mixer and Dump Setup flapper of the weigh hopper and is not dumped remains in the mixer The material is not being Increase the Mixing Time in Mixer and Dump Setup Actually if you over mixed thoroughly mix material you can have the same problem If you have the blender set for Continuous Mixing then change it to Timed Mixing and adjust the Mixing Time appropriately Recorded Inventory Totals Check the blender s scale calibration and verify that the batch hopper is don t match what I ve not overfilling If the hopper is overfilling adjust your batch size If this is actually used correct then you are probably not accounting for material scrap or other items in your process Some error can be introduced by not weighing every batch Check the Recipe Page Max Hopper Weight Stop the Blender and then Start it again This causes the blender to Exceeded Alarm continues perform an automatic feeder calibration If
36. ce Delay fax Page 62 of 118 3 Select a feeder 1 6 by touching the Select Feeder box 4 The current settings for the hopper that you have chosen will now be shown on the screen 5 Make the necessary adjustments to the Stop Continue if Out of Material Alarm No Alarm on Out of Material and Out of Material Alarm Silence Delay 0 60 seconds settings Once the settings for these features have been set on the displayed feeder select a new feeder to configure as desired 6 Press the Done key at the bottom to exit this screen An alarm message will be shown if any alarm condition occurs A message will pop up on the screen until the alarm condition is resolved The operator can press OK on this pop up to hide the screen temporarily but if the alarm condition is still unresolved then the message will reappear after a short delay During an alarm condition not only will a visual alarm show up on the screen but also an audible alarm will sound The audible alarm will sound for 10 seconds and reappear every 30 seconds until the cause of the alarm is resolved The following is a list of all alarm names and descriptions e Hopper 1 6 Out of Material This alarm indicates that a hopper is out of material and signals the operator that they should check the resin system HOPPER 1 Out of Material e Max Hopper Weight Exceeded check batch size This alarm indicates that the weight in the wei
37. ch It is assumed the regrind has been generated from pre blended production and already contains the same color and or additives Please see next page for example calculations setup Page 70 of 118 SGB Batch Blender with Mitsubishi Controller Example calculations of a five 5 component blend in Quick Set Virgin NAT 22 Additive1 ADD 5 00 of virgin component Regrind RGD 30 00 of total batch Additive2 ADD 2 00 of virgin component Additive3 ADD 1 00 of virgin component Batch Size 10 00 Ibs Total available 100 00 Regrind 30 00 Balance 70 00 Virgin Additive 1 Additive 2 Additive 3 70 00 Virgin 5 of virgin 2 of virgin 1 of virgin 70 00 Virgin 5 100 x virgin 2 100 x virgin 1 100 x virgin 70 100 100 virgin 5 virgin 2 virgin 1 virgin 70 108 virgin 70 Virgin 70 108 64 81 Virgin 64 81 of batch Additive1 5 of 64 81 3 24 of batch 5 of virgin Regrind 30 of batch Additive2 2 of 64 81 1 30 of batch 2 of virgin Additive3 1 of 64 81 0 65 of batch 1 of virgin Virgin Additive 1 Additive 2 Additive 3 Regrind 100 64 81 3 24 1 30 0 65 30 00 100 N SGB Batch Blender with Mitsubishi Controller Page 71 of 118 wT Typical Batch Size SGB 450 3 Ibs SGB 900 8 Ibs SGB 2500 4000 5000 35 Ibs 5 8 17 Batch Size Menu The SGB blending system is a gravimetric
38. commended adjacent to the blender The panel can be unplugged and removed if necessary The controller includes an embedded computer This design provides excellent blender performance along with an easily replaceable control panel in the unlikely failure of any computer or electronic part The display menu format is very simple After installation and setup simply enter in the recipe and start the blender If it is desired to have a local display and control of the blender closer to a remote operator station an optional RS422 remote control panel RCP is available N SGB Batch Blender with Mitsubishi Controller Page 19 of 118 Sy Typical Setup Screens sain Ne Atorm 3 ee Recipe Sa Ja Format TE m i Calibration a Tes i etup Hiner and Dume Setup EE FS40 Config 10k m Units a Agtyork Bone cone ns Try x Wing TES Mixing Time aH seg batch size anatie Remix Time HH see inventory shutdown anranmEN etoh Ready Disabled Dump Time ae Sec FRutoStart Disabled F940 Version Main 1 1 Dump Delay a see PLC Bl
39. controller that there is room in the mixing section to accept a batch of material When the controller has determined that the mixer is ready for an additional batch of material the controller will begin metering material into the weigh hopper assembly 5 8 13 Standard Run Time Displays While the blending system is in operation there are a couple of displays available to the operator These displays are selected simply by pressing the NEXT key when the unit is running The default display shown when the blender is in run mode is the Recipe Screen The Recipe Screen indicates by feeder number the amount of material metered into the weigh hopper assembly by that particular feeder This display is updated after each component dispenses its specified amount The ingredient weights Unit Values are in pounds unless the metric display is selected Pressing the NEXT key when in the default recipe mode display will toggle to the next screen which is the Inventory Display This can be done at any time but if the blender is in a critical mode such as dumping and updating inventory etc it may ignore the keystroke Simply press the NEXT key again the Inventory screen will be displayed N SGB Batch Blender with Mitsubishi Controller Page 67 of 118 wT Average Batch Time Batoh Pounds Used I t HHHHHHHE HH 2 ESTIEU ino HHMAHH HHI EHH 4 5 Blender Maximum Rate o ct 3 TULL mer oe 5 HHHHHHH HH
40. controller will ask you to replace the weigh hopper in the blender and press OK to complete the calibration 7 The controller will verify that the calibration was done correctly by showing Calibration Successful Enter in the SCALE CALIBRATION Calibration Weight Current Loadcell Bits ae Eor Ne oe HEHEHE Lbs alibration Press here to Load Cell Bits HHHHE perform the Follow calibration Instructions Go Back to the Calibration Directory N SGB Batch Blender with Mitsubishi Controller Page 59 of 118 wT 5 8 3 Mix Timer The mix timer is the amount of time that the mix motor will mix the material after it has entered the mixing section of the SGB blender The timer has a range of 1 to 999 seconds To set the value of the mix timer the user must gain access to the Setup Menu After entering the Setup menu the user must select Mixer and Dump Setup Continuous ising i Mining Time ee sec in Ti Go Back to Remin Tine __ F sec Dump Time eee ean Setup Directory Dump Delay wae seo Dump cyeles __ Miser Dump Time Eu Sec Selecting Mixing Time from the Mixer and Dump Setup menu will allow the operator to view the current time setting for the mix timer and to adjust it as needed The mix timer is set to a default time of 10 seconds This time can be adjusted up or down depending on the amount of mixing needed for the materials bein
41. d fittings 2 3 Mechanical Installation Blenders may be mounted on the machine a stand or a mezzanine Be sure it is securely attached and additional bracing is used if necessary The sections on the following pages explain general installation rules Read manual thoroughly before installing blender Use approved safety straps or chains to lift the blender at the marked lifting points 2 4 Safety Considerations The terms NOTICE CAUTION WARNING and DANGER have specific meanings in this manual See Section 11 for a complete list of specific safety warning information A NOTICE is used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property A CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury AN EN A WARNING indicates a potentially hazardous situation which if not b avoided could result in death or serious injury A DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This word will be limited to the most serious situation s J SGB Batch Blender with Mitsubishi Controller Page 25 of 118 Sy could result or provides additional information to make a step or procedure easier to understand Disregarding information marked IMPORTANT would not be likely to cause personal injury REPORTING A SAFETY DEFECT The term IMPORT
42. d tag it out This plug may be tagged with any number of approved electrical lockout tags These tags are available at most electrical supply stores WARNING Disconnect both of these items to ensure optimum maintenance A personnel safety when cleaning or servicing this equipment 4 _ SGB Batch Blender with Mitsubishi Controller Page 31 of 118 Sy i f AA fi aml MA L Interlock Switch Electrical Disconnect Plug 2 9 Electric Safety Interlock Switch All Models A unique electric safety switch is used to shut off power to the blender any time the mixer door is opened Do not tamper or alter with this switch in any way Page 32 of 118 with Mitsubishi Controller Electrical safety interlock switch Located on mixer door WARNING always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning any product including all SGB Series blending systems Failure to do so may result in serious injury or death 3 Shipping Information 3 1 Unpacking and Inspection You should inspect your Sterling batch blender components for possible shipping damage If the container and packing materials are in re usable condition save them for reshipment if necessary Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In case of breakage damage s
43. der base stop This will allow the load cell to operate without mechanical restrictions and provide an overload safety To adjust the stop adjust the screw located on the bottom of the load cell Adjust the screw up to increase the gap and down to decrease the gap Important THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE FROM FRICTION WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF SN LOAD CELL 040 GAP ___ STOP ADJUSTMENT BOLT Load Cell Mechanical Stop Adjustment Lo Page 44 of 118 ke SGB Batch Blender with Mitsubishi Controller 4 7 4 Final Setup Connect the blender to the appropriate power source 2 Connect the compressed air piping ensuring that a 5 micron air filter is installed along with the proper water trap and lubrication unit if required Verify that 60 psi 4 14 bar of clean dry compressed air is supplied to the blender Important Again make sure that proper air supply connections are made to the blender as dirty contaminated wet air can damage blender components and can quickly cause poor performance and accuracy Make sure that the blender is supplied with clean dry 60 psi 4 14 bar compressed air 3 After powering up the blender the following screen will be shown lt i gt SGB Blender version Main 1 1 PLC Version Copyr ight HEHH H 2001 This screen displays the software version of both the PLC and the F940
44. e aa ee Dd 7 Y a a D ie 7 N E 01 Nameplate and indicator mounting plate 02 Nameplate 03 Upper polycarbonate Opti Mixer door 04 Door clamp 05 Caution label 06 Lower stainless steel Opti Mixer door 07 Mixer agitator door bushing 08 Door hinge 09 Door hinge base 9 2 3 Typical Mixer Section Rear Typical Opti Mixer Rear Assembly Detail N SGB Batch Blender with Mitsubishi Controller Page 93 of 118 10 11 12 13 14 15 16 17 o e m come 8 2 j L yi P 6 Je o 2 Ky S amp a 8 oa XN vu f ADE Yi H D qe 2 W Ae ON lan K a 0 of eo ail S P NAL C pe i 3 o oF j T Opti Mixer back plate Cover plate Back control panel Cover plate Proximity sensor Mixer high level Mixer proximity sensor mounting plate Mixer gear motor Mixer agitator shaft coupling 9 2 4 Typical Mixer Frame Page 94 of 118 SGB Batch Blender with Mitsubishi Controller PROCESSING Typical Opti Mixer Frame Assembly L N EN 18 Hinge mounting bracket 19 Mixer door clamp 20 Load cell cover 21 Opti Mixer top plate 22 Opti Mixer frame 23 Warning label 24 Opti Mixer frame side panel 25 Hinge mounting bracket 4 _ SGB Batch Blender with Mitsubishi Controller Page 95 of 118 9 2 5 Typical Gate Assembly Typical SGB Series Diamond Gate Assembly Detail 3 28 Slide gate guide rod 29 Stainless steel gate assembly base 30 Slide gat
45. e Gate Metering Assemblies 1 11 3 Weigh Hopper 1 11 4 Weigh Hopper Dump Valve 1 11 5 Mix Chamber 1 11 6 Operator Control Panel SGB Batch Blender with Mitsubishi Controller Page 13 of 118 1 11 1 Material Supply Hoppers The material supply hoppers are located on top of the blender frame These hoppers store a supply of material for the individual metering devices They are sized based on the total throughput of the blender The SGB blending system does not include any level indication devices on the unit Optional low level sensors are available The blender controller will alarm if it runs out of material while trying to make a batch but low level sensors will alert floor personnel to the problem sooner Each hopper is equipped with a sight glass and or access door a HINGED POLYCARBONATE ACCESS DOOR DOOR LATCH PNEUMATIC SAFETY SWITCH IF EQUIPPED OLDER MODELS ONLY IGHT GLASS IF EQUIPPED DRAIN PORT WITH PLUG Typical Material Supply Hoppers Page 14 of 118 SGB Batch Blender with Mitsubishi Controller 1 11 2 Slide Gate Metering Assemblies Air operated slide gates are provided to meter the majority of pellet ingredients on the SGB blender Important The metering range assumes t4 diameter free flowing plastic pellets weighing approximately 35 Ibs cu ft This is meant to be an approximate sizing recommendation and can vary with different bulk density resins pellet configuration etc
46. e stop stroke limiter 31 Retaining clip 32 Slide gate air cylinder 33 Slide gate air cylinder pneumatic connector fitting 34 Slide gate air cylinder pneumatic barb fitting 35 Slide gate assembly material chute deflector 36 Notice warning label 37 Pin 38 Diamond v gate metering slide gate 9 2 6 Typical Supply Hopper PN Page 96 of 118 ke SGB Batch Blender with Mitsubishi Controller Typical SGB 450 Series Hopper Assembly Detail TOP OF MACHINE 40 Mild steel hopper cover 41 Hopper insert square to diamond polyurethane 42 Mild steel hopper 43 Gasketing 44 Polycarbonate access door 45 N A 46 Polycarbonate hopper sight glass 47 Blow off tool holder 48 Blow off tool 49 Drain plug 50 Cleanout door clamp 51 Optional low level proximity sensor mount 9 2 7 Typical Weigh Hopper J SGB Batch Blender with Mitsubishi Controller Page 97 of 118 Typical Weigh Hopper amp Load Cell Detail SS Ve a i TZ oe i ae a gt 1 ial TE L a8 amp lt A amp at 52 Left weigh hopper bracket 53 Inside mixer plate 54 Weigh Hopper 55 Weigh hopper discharge air cylinder pneumatic connector 56 Weigh hopper discharge air cylinder 57 Weigh hopper discharge air cylinder mounting bracket 58 Weigh hopper discharge hinge pin bolt 59 Weigh hopper discharge flapper 60 Right weigh hopper bracket 61 Spacer 62 Load cell s 63 Load cell mou
47. e that the maintenance personnel be familiar with not only the internal workings of the control panel but also with the input and output signals to the SGB unit This section includes the following e Internal components of the control panel e Input signal to the control panel e Output signals from the control panel 6 6 2 Internal Components of the Control Panel Note See Section 12 2 for complete electrical schematics This section describes the internal components of the SGB blending system control panel It is not the intent of this section to completely familiarize the reader with the details on industrial control panel construction or standards but simply to familiarize the reader with the major components inside the SGB control panel The customer must supply 120 1 50 or 60 or 220 1 50 or 60 via wires L1 amp L2 N Please insure that the earth ground connection is properly connected to an established earth ground Power on is indicated by a lighted on off switch Slide gate below mixer switch controls position of optional slide gate Safety Active light displays status of safety interlock circuit Audible alarm horn alerts operator to blender fault 6 6 3 Input Signals to Programmable Controller Page 82 of 118 The SGB blending system has two main input signals that it uses from the blending process the mix hopper high level signal and the weigh hopper load cells This of course does not include
48. e the function of the safety devices N SGB Batch Blender with Mitsubishi Controller Page 29 of 118 wT 2 8 2 Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and the manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial Council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the SGB blending system however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices 2 8 3 Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a m
49. e when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications UNPLUG OR OPEN TAG and LOCK ALL DISCONNECT DEVICES before working on equipment You should remove the fuses and carry them with you GROUND your equipment properly before applying power Use extreme caution when working with your equipment Keep body parts tools clothing and debris away from vacuum inlets and moving parts Do not jump or bypass any electrical safety components Do not restore power until you remove all tools test equipment etc and the blender and related equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment N SGB Batch Blender with Mitsubishi Controller Page 5 of 118 wT Sterling SGB E Series Blenders This blender is manufactured by ACS Inc at the ACS Wood Dale facility ACS Inc 801 AEC Drive Wood Dale IL 60191 Phone 630 595 1060 Fax 630 595 6641 The equipment is distributed in Europe by our European facility ACS EUROPE Daniels Industrial Estate BATH ROAD Stroud Gloucestershire England GL5 3TJ Phone 44 1453 768980 Fax 44 1453 768990 la Page 6 of 118 SGB Batch Blender with Mitsubishi Controller Annex B Information The following design information is provided for your reference DOE OY OV Be NO 2 11 12 13 14 15 16 17 18
50. ectory Fegrind Regrind Reagrind ne Regrind configured as Regrind Fegrind 12 1 3 Customer Setup Menu Units This screen allows the user to change the blender s unit of measurement The entire blender can be configured in either Kgs or Lbs while the Target vs Actual data can be configured for either regardless of the blender s units Change UNITS Blender s Blender Data in Kgs Units Display Target Actual in Lbs Change Target vs Actual Units Go back to Setup Directory Alarm This screen allows the user to configure the feeder type Setup for each feeder configure whether a feeder will retry during the metering of a batch and enable or disable the Out of Material alarm for any feeder If a hopper is set to Continue on Out of Material then the blender will continue to meter the rest of the batch even if this hopper runs out of material To configure each hopper perform the following steps 1 Select a feeder by touching the Select Feeder A SGB Batch Blender with Mitsubishi Controller Page 109 of 118 wT box 2 The current settings for that hopper will be shown 3 Make the necessary adjustments and select a new feeder to configure if desired 4 Hit Done to exit Enable or Disable Retries Enable or Disable Alarms Select a Feeder to Select Feeder Configure Ha t ae l ateria Go back to Setup Silence Delay Alarm This screen
51. ed in this warranty Many types of Sterling equipment carry an additional one year service policy Consult your Sterling sales representative for specific details N SGB Batch Blender with Mitsubishi Controller Page 101 of 118 wT Safety Tag Information 11 11 1 SGB Blender Safety Tags Pinch Point Slide Gate Read Operation and Installation Manual Shear Point Earth Ground Rotating Mixer High Voltage Protected Earth Inside Enclosure Ground Shear Hazard Rotating Auger Lifting Point Page 102 of 118 gt SGB Batch Blender with Mitsubishi Controller 11 2 Pushbutton and Touchscreen Tags Button Function Pt Turns power on to the blender controller Found on back of controller Power On Oo Turns power off to the blender controller Found on back of controller Power Off Abort Stops blender amp re starts controller Press to move back one screen level in controller function Move forward one screen level in Hear controller function Fush toa Start or stop blender with current program parameters Can erase current settings for one recipe or all recipes amount and has been stopped Stops blender operation after current E E F 4 inventory shutdown if used is vender Bender completed This screen will be displayed J SGB Batch Blender with Mitsubishi Controller Page 103 of 118 we 11 3 Blender Identif
52. eder Pen Test Alarm Open or Close r GA i Ga NA oat as Output A IPEN OPEN OPEN OPEN Outrut Weigh Hopper 1 2 3 4 Be Press Hop Current Hopper ree EES PEN WEIGHT 3 Start or Stop OPEN OPEN HOPPER a Weight Mixer Motor z moe i 4 Press to Open or Close LOSE MIX GATE iF Go back to Setup Directory Mixer Knife Gate Low Level Prox Status The dump valve opens as soon as the Press to Open Feeder key is pressed This easy feeder clean out option also serves as a means for emptying a batch that is held in the weigh hopper if the Press to Open Weigh Hopper key is pressed when the blender is stopped Touch the picture of the hopper you wish to open or close to select the feeder you desire to empty and close the dump valve Touch the Done key to return to the recipe menu After entering a recipe the operator will restart the blending system putting it back in normal operation Before starting SGB blending systems each ingredient hopper in the current recipe must contain material Virgin material must be loaded in hopper 1 and hopper 3 should only be used for regrind Once the operator initiates the run mode of operation the blending system controller will begin monitoring the mixer high level switch Nothing will happen until the mixer high level switch is uncovered This tells the controller that the mixing chamber is capable of holding another batch of material Once the mixer high level switch is uncov
53. en nenknenuas 48 5 4 SGB Series Control System Menu Structure ccceeeeeeee 51 5 5 Blender CalibralOMmnccc tcc sien eadesilre tatu side adits aed nie mabe diss 52 5 6 Controller Mode Setup ciccssenemneninnniveneenenieel 54 5 gt Color GAMO es cece cask Conk cest esi cest desi cent Cost ceti desl cent evi cei desl centesEads 56 5 8 Additional Operation Features ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeees 58 5 9 Stroke Limiters for Metering GateS cccccceceeeeeeeeeeeeeeeeeeeeeeeees 77 6 Maintenance ee aa ste senat E teh atta Mie ca 79 6 WOK RUES visas u csi ade aaekatakbnec ee bbc eneeeseunsancdsteneaeembenetes 78 6 2 Maintaining BlenderS cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 78 6 3 Controller Setup ais tratezatiercts catlontetatd natn catiacattaedniedtstvesseubsuedembiiaes 79 6 4 SGB Series Blender Menu Structure ccseeeeeeeeeeeeeeeeeeeees 80 6 5 MCh ANIC ates ccs cee E A ERR 81 6 6 gt Electrical srei eeen teet eee eten teree tenre eaten ten tet 82 6 7 Pneumatic System Maintenance cccccceeeeeeeeeeeeeeeeeeeeeeeeees 84 T WTOUDICSHOOUNG icity eh te ec lee ta Ri te Meal as 85 7 1 Description and Objectives 85 3 BIlOndSr OpliONS xc cresssenententenarcvmcreternut tyaensanneiseer aiden aaa 89 O Opa e PANS sessile ered octrereenes sor sete crab a E a E ees 90 9 1 Spare Pants Listede edd a aiii aiiai 90 9 2 Model SGB Blender System Component De
54. ender The air supply should be filtered through a 5 micron air filter with a water separator Oil should not be used unless air dryers are installed on the compressed air supply In this situation an oiler may be required on the blender to keep the air cylinder seals lubricated Important As this blender uses air for blender metering functions it is very important to supply clean dry air to the blender Dirty or oily air can affect blender accuracy result in poor performance i and cause injury Provide a 5 micron air filter on the air supply to the blender and be sure excess oil is removed DRY 60 psi COMPRESSED AR TR CUSTOMER SUPPLIED COMPRESSED AIR COMPONENTS SGB BLENDER Sterling provides all pneumatic lines on the blender piped to a single 4 NPT standard pipe thread fitting The SGB blending system requires approximately 1 cfm 1 7 m hr 60 psi 4 14 bar maximum air pressure for proper operation The working pressure of the blender cylinders is not to exceed 60 psi 4 14 bar This is adjustable by the regulator supplied on the rear panel of the blender It is important to prevent fluctuation in the air pressure to the blender by not installing the unit on an airline If this is the case an accumulator tank with a check valve may have to be provided by the customer to ensure the blender a steady air supply CAUTION To prevent damage to the equipment do not exceed 60 psi 4 14 bar air pressure gt Always di
55. ender Version anna a Dump Cyeles REE 2450 F940 Date amp Time zx Mixer Dump Time Eg SBE PLC Hour feta Se ae eae otra op Done At midui nd noon one Be bene ender Data in Kgs ike Brender llla aie a Display TargeteActual in Lbs open foren aren oren durer HOTE If Blender F slender Lf Ne NE 4 ither 2x Press to Hop Wt OFEN WEIGHT OPEN OPEN HOPPER HHE E ey Be Press to Lbs START MIXER Done 4 Press to GLOSE MIX GATE TF Done ALARM FLAGS amp FEEDER SETUP P Bhoy LHEMMSSS PM Blender dHH Select Feeder POWER OM Day Hour 4 Alarm on Out of Material Out of Material Alarm Silence Beis cen Pom oo Seale Calibration Direct Seale Readout Feeder Calibration SCALE CALIBRATION Hort we sec iti at F i 9 eal Aa atela HEE BEA Les Select Feeder Hor2 wtfsec tit tit Calibration Weight calibration for New HEHEHE Lbs Hor3 wt sec Hit HH Calibration naiai Ar B Horg wt sec ttt ttt Load Cell Bits HHHH Zero Bits mmun n snnun n welaht Hors we sec BEHE Cal Bits LSRIREH i 1 SAIREH H REE HHH Hor wefsec RE HH scale calibration Current Bits unnt nunna t 2x We ight HHH HHH Lbs Hin tinh Lbs Ok Total Weight nin tnt Lbs Total wt minus tare wt HHH HHH Lbs Hopper Weight ttt Hon Lbs an OF 1 Ox Done Feeder Calibration Setup Done Page 20 of 118 SGB Batch Blender with Mitsubishi Controller Typical Operator Screens SGB
56. erator of the problem The Accept New Recipe button is only shown if the recipe is valid and different from what is currently running on the blender Recipes can also be changed while the blender is running The new accepted recipe is entered at the beginning of the next batch This allows the operator to modify the new recipe without affecting the blender until they hit the Accept New Recipe button 8 Recipe entry is complete 9 To start the blender press Push to Start or Stop button Other questions regarding features are answered in the Detailed Control Setup Section 5 7 Color Change The color change procedure is meant for use with the basic SGB Blender This procedure assumes that the color component of the blend is in an additive ingredient hopper 2 4 5 or 6 Note The blender must be stopped to make color changes The processing machine can operate on virgin material only during this procedure with an optional quick color change bypass tube that can be installed to bypass the blender Contact the factory for details 1 Disable and clean any color loading equipment Please refer to the loading equipment manual for any clean up recommendations 2 Using the blender Abort or Push to Start or Stop key put the blender in stop mode After the cycle has completed switch OFF the main power switch and unplug the blender power supply 3 Open the upper mixer access door This shuts
57. ered and the weigh hopper has dumped the system will meter the ingredients from the supply hoppers through the metering units into the weigh hopper Each component will be metered individually to allow accurate weighing of the material Once the final ingredient specified in the recipe has been metered into the weigh hopper the controller will take a final weight reading of the weigh hopper This will start the Dump Delay timer See Section 5 8 9 Once the dump delay timer has timed out the controller will activate the weigh hopper dump valve initiating the weigh hopper dump cycle The open weigh hopper dump door will allow the material to drop into La kA SGB Batch Blender with Mitsubishi Controller the mixer section of the blender If the dump delay is set the mixer will start before the weigh hopper dump will open for the selected time The blender will sit at rest until the high level sensor in the mixing chamber is uncovered to start another weigh cycle Unless the Re Mix timer is set to a value other than 0 and times out to restart the mixer to run for another mix cycle The level sensor is located on the back wall of the mixer chamber If the sensor is covered with material the indicator light on the back of the sensor will be lit Once this sensor is uncovered the indicator lamp on the back of the level sensor will go out This level sensor must be uncovered for approximately 1 2 seconds to indicate to the
58. esigned and manufactured by Sterling to ensure proper results for your application 1 4 Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with this equipment and help your organization get the maximum service from your equipment If you have any questions regarding installation service repair custom equipment or applications please do not hesitate to contact us for the information required Prices for additional equipment accessories or repair parts will be furnished promptly upon request NOTICE If you desire to use a blender for an application other than that for which it was purchased please contact your sales representative or our factory to verify compatibility of the equipment with the new process Misapplication of the equipment could result in injury to the operator or damage to the equipment Page 8 of 118 gt gt SGB Batch Blender with Mitsubishi Controller 1 5 Necessary Documents The documents listed below are necessary for proper installation operation and maintenance of SGB Series Gravimetric Batch Blenders You can obtain additional copies from the Service Department at Sterling or ACS Europe Make sure that appropriate personnel get familiar with these documents This Operation Installation and Service manual Electrical schematic and connection diagrams Pneumatic circuit drawing Electric motor and controller information sheets if equipped Operation
59. etc must be powered by another power source As well as possibly overloading the transformer the additional equipment may induce power line noise that may affect the operation of the blending system The transformer will be mounted and wired by the customer or your installer If company or local codes require fusing or disconnects these items must be supplied wired and mounted by the customer Each Sterling blending system MUST be connected to a separate source of power Do not connect other electrical equipment especially self contained hopper loaders on the same line as the blending system Ensure that the power entrance location on the blender panel remains unchanged Make sure that the proper size wire and proper wire routing techniques are used when installing the supply wiring to the control panel Care must be taken to ensure that the supply wiring does not interfere with the low voltage DC wiring The blender is equipped with a plug that functions as the disconnect device The mating receptacle must be installed no higher than 5 feet 1 6 m above the floor Make sure your installation conforms to your regional electrical standards Power Receptacle Installation Lo Page 42 of 118 gt SGB Batch Blender with Mitsubishi Controller 4 6 Pneumatic Installation The SGB blending system uses plant supplied compressed air to operate the metering and dump valves on the blender CLEAN AND DRY air must be supplied to the bl
60. eteedeeseneeteeeeneedeees 9 1 6 System Capabilities rs occ cecteret cnet evehescresetdeerererenereseeenereseeanereneeanereies 9 1 7 Equipment Covered by this Manual cceeeeeeeeeeeeeeeeeeeeeees 9 1 8 SGB Series Weigh Blender Mechanical Features 5 10 1 9 SGB Series Weigh Blender with Mitsubishi Touch Screen Control Feat reS saena e a a a R 11 1 10 SGB E Series Specifications eee eeeeeeeeeeeeeeeeeeeeeeeeee 12 1 11 Model SGB Blender System Component Description 13 1 12 Pneumatic Slide Gate Below Mixer Optional eee 23 2 Saey a are cna ace hese te itachi Rhee is WAN a cce iM Neste 24 Bad CVV ORK RUES cena cenccsince avec euecens eens E EEEE ook aes aah eens feces 24 2 2 Tools and Equipment Needed cceeeeeeeeeeeeeeeeeeeeeeeeeeeees 25 2 3 Mechanical Installation ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 25 2 4 Safety Considerations cccccccceeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaea 25 2 5 General Responsibility 2 2 c c ceecsceeteceeeeeteeceeeeceeeeeeeees 26 2 6 Operator Responsibility cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeees 27 2 7 Maintenance Responsibility ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 28 2 9 Safee ia a silat Oe Sh ee 1s Ee 29 2 9 Electric Safety Interlock Switch All Models 32 3 SNIPING Intormati M eais a eter oa tence a i
61. fore operating Sterling assumes no responsibility for any damages resulting from improper installation or improper handling during installation Make sure that the blender is securely mounted to the floor before installing loading equipment loading with material and starting Make sure that the blender location is adequately away from high traffic aisles and that fork trucks etc cannot damage the blender Ensure that normal day to day operations will not place the blending system at risk of damage TYPICAL CENTRAL BLENDER LAYOUT Page 40 of 118 Blender Pneumatic Slide Gate Below Mixer 4 Take off Compartment 7 P Surge Bin Floor Stand PN SGB Batch Blender with Mitsubishi Controller 4 3 Installation Overview This section will familiarize the reader with commonly used procedures for blender installation After reading this chapter the reader will be familiar with the installation requirements for all SGB blenders 4 4 Mechanical Installation The installation procedure should be used as a general guideline for the proper installation steps required to install the SGB blending system Remove crate from around blender Secure strap of proper lifting capacity to both lifting lugs Lift blender until strap is taut 1 2 3 4 Remove bolts attaching bottom of blender to shipping skid 5 Lift blender and position over machine throat or floor stand 6 Set in position and secure by t
62. g blended It is recommended that the mix time be held to the minimum as segregation can occur from over mixing if the material bulk density and pellet configuration varies with materials in the particular blend being processed 5 8 4 Re Mix Timer Page 60 of 118 In some applications the SGB blender will require the use of the re mix timer Some materials tend to separate if they are mixed too long This is possible when a processing machine is running at a rate significantly below the capacity of the blender With external vibration the heavier pellets will tend to flow to the bottom of the mix chamber before the lighter material This will occur even though the mixer is in a static mode By re mixing occasionally this situation will be prevented The re mix timer will start another mixing cycle if the blender has been idling long enough for the re mix timer to time out The re mix timer may be set on the Mixer and Dump Setup screen from 1 to 999 seconds Setting the re mix timer to zero will disable this function If the re mix timer is disabled the controller will run only a single timed SGB Batch Blender with Mitsubishi Controller mix cycle after each dump of the weigh hopper To view and change the value of the re mix timer refer to the Mixer and Dump Setup menu All current values for Mixing and Remixing Times will be shown on this screen The re mix timer default value is factory preset at Zero 5
63. ge of the total batch 5 3 3 Parts Mode Often used in Compounding Applications The Parts recipe entry mode lets the operator enter in values based on a parts ratio rather than a percentage Each entry can be up to 999 99 and the total of all hoppers does not have to be 100 After all values are entered the total parts are calculated The individual hopper target is then calculated based on each hopper s entered parts These parts represent ratios of the total batch For instance Hop 1 300 parts Hop 2 100 parts Hop 3 10 parts Hop 4 5 parts This would mean that if the batch was divided into 415 parts then Hop 1 would make up 300 of those parts Hop 2 would make up 100 Hop 3 10 parts and Hop 4 5 parts JAA SGB Batch Blender with Mitsubishi Controller Page 49 of 118 wT The preset part will be divided by the total of all parts with each part representing the calculated weight for ratio control Example of a 5 component Blend in Parts Mode Feeder Tag Preset Part hee Virgin 1 7 200 7 200 10 000 Regrind 2 2 000 2 000 10 000 Color 3 500 500 10 000 Additive 4 300 300 10 000 Total 10 000 5 3 4 Switching Modes Recipe Modes can be switched while the blender is making a batch At any time the operator can switch the recipe entry mode without affecting the current batch being made The recipe mode is part of the New Recipe and is separate from the running recipe
64. gh hopper has exceeded the maximum allowed weight This alarm can happen if the operator changes material density and does not perform a feeder calibration but will usually be automatically fixed after the first batch As long as this alarm doesn t continue to reappear then the operator should not be concerned If the alarm continues to occur then the operator should have maintenance check the blender MAX HOPPER WEIGHT EXCEEDED check batch size N SGB Batch Blender with Mitsubishi Controller Page 63 of 118 wT Page 64 of 118 Calibration Error Clean out hopper and check calibration This alarm indicates that the maximum empty weight for the weigh hopper has been exceeded The blender will automatically tare up to 0 25 Ibs of material but if this weight is exceeded then an alarm will appear This alarm is most commonly caused by a build up of sticky material in the weigh hopper and can be corrected by simply cleaning out the weigh hopper If this does not correct the problem then the scale calibration should be checked by maintenance CALIBRATION ERROR Clean out hopper and check calibration Power Interruption while metering a Batch This alarm indicates that the blender s power was turned off while the blender was making a batch The batch accuracy is not effected as long as the blender is configured for AutoStart The blender will finish the last batch accurately even if the material was dumped into the mixer w
65. h material in the Initial of Target to Meter These are found under Feed Algorithm batch Options Make small adjustments and retest A feeder is retrying more Increase the Gate Cycle Time This is found under Feed Algorithm than 2 4 times Other service problems or questions can be answered by contacting the Sterling Service Department Page 88 of 118 SGB Batch Blender with Mitsubishi Controller 8 Blender Options The following is a list of options which your blender may have been equipped with Regrind Auger Metering RAM Used for feeding difficult regrind materials Low Level Sensors Detects material supply problems before blender runs out Remote Touch Screen Interface Allows control of blender from a second location up to 50 feet 30 meters away Mezzanine amp Floor Stands Supports blenders in mezzanine mount and freestanding applications Take off Compartments Allows material to be metered into a vacuum conveying system Slide Gate below Mixer Ensures blend homogeneity CL 25 Pneumatic Loader for Additives Compressed air loader to load low percentage additives into the blender JA SGB Batch Blender with Mitsubishi Controller Page 89 of 118 we Spare Parts 9 9 1 Spare Parts List SGB Series Gravimetric Batch Blending Systems v Please see Section 9 2 for parts identification and exploded views Model SGB 450 CalexModule i y Calex Module Model SGB 900 PartNo
66. h the Accept New Recipe on the Recipe Screen before the change happens This allows the stored recipes with different Inventory Shutdown settings to easily be loaded without the operator having to reconfigure the blender every time they want to load a stored recipe This enables the blender to have a batch already made in the weigh hopper while the mixer is full Enabling this feature dramatically increases the maximum achievable blender rate By enabling this feature the blender accurately finishes a batch that was interrupted by loss of blender power This option starts the blender if it was running prior to power loss It does not turn on the blender if it was previously stopped prior to power loss 4 Press the Done key two 2 times until you return to the Recipe page 5 When you are in the Recipe screen touch the hopper box 1 6 that you want to change 6 Enter in the new value 0 999 99 and hit the enter button arrow 7 After you have entered the values for all of the hoppers then hit Accept New Recipe and the recipe will be entered N SGB Batch Blender with Mitsubishi Controller Page 55 of 118 wT Note The blender monitors the operator s entries and determines if the recipe is valid before accepting the new recipe If there is an error such as the recipe does not add up to 100 and the blender is in Percentage Mode then a message is shown on the Recipe screen to alert the op
67. hen the power was turned off POWER INTERRUPTION While metering a Batch PLC Battery Low PLC battery is low and may cause the blender to lose both the program and the blender configuration Notify Maintenance immediately PLC BATTERY LOW Inventory Cleared This is only logged in the Alarm Log and does not cause a pop up message or audible alarm Each time the inventory is cleared the time and date are logged to the Alarm Log An alarm will sound and a screen will pop up when Auto Inventory Shutdown has been reached la SGB Batch Blender with Mitsubishi Controller e E Stop Screen The blender is equipped with an E stop switch that removes the power from all mechanical outputs The E Stop Screen appears along with an audible alarm whenever the E Stop is activated The operator can not access any screens until E Stop is deactivated The Panel View will then put the screen back to the display that the operator was on prior to hitting the E Stop E STOP HAS EEEN ACTIVATED 5 8 10 Additional Control Functions The objective of this section is to familiarize the reader with the SGB blender recipe menus run mode operation run mode menus and displays Upon the completion of this section the reader will be familiar with the recipes and run mode displays that are available on one blender including the recipe book and recipe storage facilities Topics covered in this section are e General Operation e Recipe Menu
68. hortage or incorrect shipment refer to the following sections J SGB Batch Blender with Mitsubishi Controller Page 33 of 118 we 3 2 In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment The Carrier then assumes full responsibility of the shipment Page 34 of 118 Mi Mi Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling before the transportation company inspection and authorization File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise Sterling regarding your wish for replacement and to obtain an RMA return material authorization number SGB Batch Blender with Mitsubishi Controller Parcel Post Shipment M Notify Sterling at once in writing giving details of the loss or damage This information is required for filing a claim with our insurance company Mi Hold the damaged goods with the container and packing materials for possible inspection by postal authorities United Parcel Serv
69. i a ees aut 33 3 1 Unpacking and IMS POClOMec d sscessetccohecteiaididseniieiaieloidideaeis 33 3 2 Inthe Event of Shipping Damages 34 3 3 If the Shipment is Not Complete cccceceeeeseeeeeeeeeeeeeeeeeees 35 3 4 Ifthe Shipment is Not Correct 2 0 0 0 ceecececeeeeceeeeeeesseeeeeeeeeeees 36 S70 REM Se eterea ee ta banet e e dard eee ett 36 4 Installation amp Setup scccsosna9ss0sieanauseececcactemsadeadarvansenbhuseennemun canlaesunans 37 4 1 Chapter Description and Objectives ccccceceeceeeeeeeeeeeeeeeeeeeees 37 4 2 Site Requirement cccccccccceeccceceeeeesseeeeeeeeceeeeeeessseeeeeeeeeeenees 37 4 3 Installation Overview isissxscececessseusdevecesacencseseseuapesaunnssestsesapesaeesecesteen 41 4 4 Mechanical Installation ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaea 41 4 5 Electrical Installation cccccececececeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeesenees 42 4 6 Pneumatic Installation ccccceccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeea 43 4 1 Blender Se Up serron aaa e a a 43 N SGB Batch Blender with Mitsubishi Controller Page 3 of 118 wT Table of Contents 5 Oper OT sracess deren pe sAeh tens e a alte oe OM rE ON At 47 5 1 SGB Blender Sequence of Operation ccseeeeeeeeeeeeeeeeeees 47 5 2 Quick Stafl PrOCeGUEC st c0css shosualseaicesscentcesicenepeaeeesisestceseseuacenepestces 47 5 3 Recipe Entry FormatS 242 04 5040 n0nene n
70. ication Serial Number Tag Located on back of mixing chamber C SGB Series Blender Model Number SGB 900 Max Blend Capacity 318 KG HR Serial Number 060701R Date of Manufacture 06 2002 Over current Protection Device s 4 5A Total Frequency 50 60Hz Compressed air supply 4 14 bar 60 psi Mixer Speed 16 RPM Blender Mass 400 Ibs 180 KG Electrical Diagrams amp Pneumatic Diagram 5200 W Clinton Ave Milwaukee WI USA 414 354 0970 Page 104 of 118 SGB Batch Blender with Mitsubishi Controller w 12 Appendix Important Hidden programmable features and hidden menu pages should not be made available to floor operators These pages include the Service Supervisor Information addendum located in this section Unauthorized changes to these factory settings by inexperienced operators may prevent the SGB unit from operating properly and may void part or all of the warranty 12 1 Addendum Service Supervisor Information Note Should not be used by untrained personnel blender controller and or program can be compromised 12 1 1 Programmable Settings N SGB Batch Blender with Mitsul wT SGB The SGB Series blender software program has been designed to allow some customizing to achieve certain desired operating parameters The following is a listing of the selections that are field programmable followed by the procedure for doing so This menu is accessed by pressing the Sterling icon when i
71. ice Shipment M Contact your local UPS office regarding damage and insurance claims M Retain the container and packing M Notify Sterling at once 3 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have Sterling SGB gravimetric batch blender components Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings NQNNARA Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify Sterling immediately of the shortage N SGB Batch Blender with Mitsubishi Controller Page 35 of 118 wT 3 4 If the Shipment is Not Correct If the shipment is not what you ordered contact Sterling immediately For shipments in the United States and Canada call 1 800 233 4819 for all other countries call our international desk at 001 630 475 7491 Include the order number and item Hold the items until you receive shipping instructions 3 5 Returns Important Do not return any damaged or incorrect items until you receive i shipping instructions from Sterling Notes Page 36 of 118 gt SGB Batch Blender with Mitsubishi Controller Installation amp Setup 4 4 1 Chapter Descriptio
72. ightening four bolts 7 Remove lifting strap y CAUTION Lifting Lug Blender Lifting Lugs 1 on each side 8 Mount the material conveying system receivers on the top of the blender supply hoppers 9 Align the weigh hopper on the load cell brackets Carefully adjust the load cell brackets to ensure that the weigh hopper is centered on the brackets without rocking If for some reason the locating tabs do not align with the weigh hopper they can easily be loosened and adjusted Important Use extreme care when tightening bolts on top of the load cells so you do not spring the load cells The load cells are extremely delicate and should be treated with care 10 Check the slide gate metering assemblies to ensure they are not damaged and will slide back and forth freely These are the most important items on the blender besides the load cell and weigh hopper 4 _ SGB Batch Blender with Mitsubishi Controller Page 41 of 118 assemblies 4 5 Electrical Installation The standard Sterling SGB blending system is designed to operate on 120 1 60 supply voltage 220 1 50 CE models are also available The current requirements vary with the blender s size and throughput rating For exact current requirements check the blender serial number tag located on the rear plate of the mixer section If a step down transformer was provided it should never be used to power anything other than the blender Loading equipment
73. l setting under Feed Calibration Options This can be observed by looking at the Hopper Weight display None of the feeders calibrate Check the Scale Calibration If this is correct then lower the Batch for Feeder Cal setting under Feed Calibration Options for each feeder This can be observed by looking at the Hopper Weight display N SGB Batch Blender with Mitsubishi Controller Page 87 of 118 wT Weigh hopper does not Check the dump time setting It may be set too short empty completely If this does not correct the problem clean the weigh hopper and recheck the scale diagnostics readout If not showing 0 zero when empty re calibrate the scale Possible solution Blender does not make Verify application is not exceeding blender capacity rate Verify additive percentage is not higher than designed resulting in excessive dispense time Verify all materials are feeding freely through the metering gates have changed the recipe All of these settings are part of the current running recipe This makes it entry mode batch size easy for the operator to load a stored recipe without having to reconfigure inventory shutdown or all of these parameters for the new recipe All you have to do is touch feeder type and alarm Accept New Recipe to load these values into the running recipe flags but the change hasn t taken place A feeder always puts too Check that the Gate Cycle Time is set correctly If it is then lower the muc
74. l and vertical pressures to the mounting flange If there is a question as to the mechanical stability of a mounting flange contact Sterling s Engineering department N SGB Batch Blender with Mitsubishi Controller Page 37 of 118 wT Verify all clearances on the top and beside the processing machine This is to insure that all motors hoppers control panels etc have adequate room for proper operation and servicing Refer to the assembly drawing with the unit for actual height and width dimensions Note Allow at least 36 clearance around blender to provide adequate room for cleaning servicing etc Using proper lifting equipment lift the blender using the lifting lugs attached to the top plate of the blender These lifting lugs can also be used to fasten horizontal or angled braces to the blender if more stability is needed Take care to insure proper orientation with adequate access to operator controls mix chamber and metering units Important Never weld on the blender support stand machine or mezzanine without first removing the control panel and verifying that the blender is properly grounded Page 38 of 118 SGB Batch Blender with Mitsubishi Controller 4 2 1 2 Mezzanine Mount In a mezzanine mount application review the following items before installation begins First verify the SGB mounting locations match the mezzanine supports Verify that the mezzanine is capable of supporting the ble
75. lear option Auto interval setup Auto start time Calibration Scale Calibration Direct Scale Readout Feeder Calibration Mixer and Dump Setup Mixing Time Remix Time Dump Time Dump Delay Dump Cycles Mixer Dump Time Timed Continuous Mixing Option F940 Config View software version Access F940 Config setup to modify time settings Units Blender data units Ibs or kgs Target vs actual data units Ibs or kgs Alarm Log View and clear the alarm log Alarm Setup Stop Continue when out of material Alarm No Alarm when out of material Alarm Silence delay User Interface Lock Lock the user interface to prevent others from making changes or viewing your blender be sure to logout after locking Page 51 of 118 5 5 Blender Calibration NOTE It is not necessary to calibrate the weight scale on a brand new blender although it is recommended that the calibration be checked periodically to ensure that the reported inventory totals are accurate Remember that in most cases a bad calibration is worse than no Calibration 5 5 1 Standard Calibration on a blender equipped with an OptiMix style mixer Recommended only if the calibration is out of spec 1 2 3 Login by touching login from the Inventory Page and enter 5413 then touch the Sterling logo to access setup Touch Calibration and then Scale Calibration Remove the weigh hopper clean it
76. lender with Mitsubishi Controller time the mixer will mix or the batch is dumped 3 Enter a Mixing Time by pressing the number next to sec this is the amount of time to run the mixer after a batch is dumped into the mixing chamber Remember that if the mix time is too long you may get material separation 4 Press the number next to sec on the Remix Time to set Re mix off time This allows the mixer to come on between batches if the blender cycle time is very slow i e if you want the mixer to come on every minute set this to 60 seconds If you don t want to use this function set the time to 0 5 Press the number next to sec on the Dump Time to set your dump time A value between 1 and 999 will need to be entered This feature is the amount of time required to empty the batch hopper Set the time so that all the material in the weigh hopper has a chance to be evacuated 6 Press the number next to sec on the Dump Delay line for the optional dump delay setting This is the amount of time to start the mixer prior to dumping material into the mixing chamber Set to 0 to disable this feature 7 Press the number next to Dump Cycles to enter the number of times that material will be dumped from the weigh hopper This allows the dump valve to open and shut repeatedly when the weigh hopper is empty to shake lose any sticking material If this feature i
77. ly skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All blenders should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual controt repetitive functions are automatic while the blender is operating An inspection report detailing the functional test is included with the blender The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation N SGB Batch Blender with Mitsubishi Controller Page 7 of 118 wT General Information 1 1 Introduction We are pleased to supply Sterling auxiliary equipment for your facility We manufacture a complete line of auxiliary equipment to satisfy all of your material handling process cooling scrap reclaim size reduction and automation requirements Please feel free to contact your sales representative or our office if you have any questions 1 2 Equipment Function All SGB blenders are designed to blend plastic pellets and regrind and supply the blended material to the processing machine Standard equipment is not designed to blend powder or any other materials 1 3 Accessories Sterling offers a variety of standard options for blenders including floor stands RAM feeders loading equipment etc All accessories are d
78. material that may cling to the dump valve To enter the dump cycle menu first enter the Setup menu by pressing the Sterling icon from the main menu Enter the password and press enter Next press the button marked Mixer and Dump Setup The display will show the Mixer and Dump Setup menu Press the Dump Cycle key to enter a dump cycle value and press enter Please refer to the menu structure tree shown on page 51 5 8 9 Feeder Alarm Setup amp Flags This screen allows the operator to configure the alarm settings for each individual feeder It can configure whether a feeder will retry during the metering of a batch and enable or disable the Out of Material alarm for any feeder If the alarm flag is set to Stop the blender will not continue It stops on that component continuing to try and meter The optional low level proximity switches have their own separate alarm The alarm will sound but does not stop the blender To configure each hopper do the following 1 Enter the Setup Menu 2 Once in the Setup menu press Alarm Setup This will take you to the Alarm Flags amp Feeder Setup screen Select Feeder Select a Feeder to Configure Enable or Disable Retries Continue if Out of Material Alarms Out af Material Go back to Setup Directory Alarm Silence Delay lt gt SGB Batch Blender with Mitsubis PROCESSING 7 Change the Alarm Silen
79. mped FEED ALGORITHM OPTIONS 10 Hop1 Initial of Target Hop2 Initial of Target Hop3 Initial of Target 100 Hop intial of Target E a a a 0 004 0 004 JAA SGB Batch Blender with Mitsubishi Controller Page 113 of 118 Hop6 Allowed Underfeed Double Gate Threshold Out of Material Retry limit before alarm 10 Batches for process rate Process Rate Filter SGB BLENDER CONFIGURATION PARAMETERS Cont d Model Number Type SGB 5000 FEED CAL OPTIONS Hop1 Batch for feeder cal Hop2 Batch for feeder cal Hop3 Batch for feeder cal Hop4 Batch for feeder cal Hop5 Batch for feeder cal Hop6 Batch for feeder cal _ oO oO gt N oO oa N N oa oa 10 MECHANICAL OPTIONS Hop1 Gate Cycle Time 0 05 Hop2 Gate Cycle Time Hop3 Gate Cycle Time f a _ f a Oo oO oO N Hop4 Gate Cycle Time Hop5 Gate Cycle Time Hop6 Gate Cycle Time Hop1 Settle Time Hop2 Settle Time Hop3 Settle Time Hop4 Settle Time Hop5 Settle Time Hop6 Settle Time Mixer Bump Time to Detect high level Number of Hoppers for display 0 25 SEE ORDER FEEDER SETUP VIRGIN ADDITIVE REGRIND Hop1 Feeder Type Hop2 Feeder Type Hop3 Feeder Type Hop4 Feeder Type Hop5 Feeder Type Hop6 Feeder Type ADDITIVE Page 114 of 118 SGB Batch Blender with Mitsubishi Controller w Service Notes N SGB Batch Blender with Mitsubishi Controller Page 115 of 118 wT
80. n LCD The SGB blending system utilizes a standardized menu format Each screen was designed to be user friendly and provide the operator with the necessary information to run the blender i 4 as Tk 2 Book I Next A typical menu is shown in the figure above This display which is defaulted to when the controller is turned on provides the operator with the following information and options The ability to change Recipe Values Accept a newly entered Recipe Start or Stop the blender Access to the Recipe Book Access to the Clean out Screen Access to the Inventory Screen Access to the Controller Setup Screen Please refer to the SGB menu structure in Section 5 4 The menu tree shows the structure for a standard SGB blender When the unit is initially installed the Clean Out menu will be used This screen is primarily used for trouble shooting the blender All outputs can be controlled manually and all digital inputs from the proximity switches can be viewed Pressing the Clean Out key when in the Recipe screen accesses this screen Warning Empty Entire pee a6 Close Message Blender a Feeder Open or Close ia Esat Blender the Weigh ess Press Press S ETest Test Alarm Hopper open laren Ii oren loten ous Output
81. n on this page Itis not necessary to perform feeder calibrations The blender will automatically learn these values during the batch Go back to Sterling Engineering Only Directory Mechanical This screen allows the user to change the number Options Screen of hoppers the predetermined gate cycle time and the mixer bump time for detecting high level The gate cycle time has been measured and set at the factory but might need to be adjusted if we change the mechanical design of the gate solenoids and air cylinders This setting will vary depending on whether you are using a gate Gate Gucle Settle Time Secs Time Mi Hoei sec e SEF sec Hope Hops Hop 4 sec LL Se ASS Go back to an Hoppers fer eee Sterling eine Engineering Page 108 of 118 itsubiSt Directory PROCESSING Controller Hope Hope va Feeder Setup This screen allows you to modify the type of each feeder In most cases the user will want to keep regrind on hopper 3 because that blender has been specifically designed to handle the regrind These settings should only be modified under special circumstances If the blender is configured in Quick Set then one hopper must be configured for Regrind and only one hopper must be configured for Virgin material If this is incorrect a message will be given on the Recipe Screen Go back to Sterling Engineering Only Dir
82. n and Objectives It is the intent of this chapter to familiarize the reader with the proper site requirements and installation procedures of the SGB blending system The information in this chapter is NOT meant to replace or supersede an established local or company implemented procedures It is meant to enhance them 4 2 Site Requirements This section describes site requirements in detail These requirements are broken down into mechanical mounting electrical connections and pneumatic connections Since the SGB is available in several different mounting arrangements it is necessary for the reader to become familiar with the different arrangements 4 2 1 Mounting Configuration The SGB System is available in 3 three basic mounting arrangements They are Machine Mount Mezzanine Mount Floor Mount 4 2 1 1 Machine Mount In a machine mounting application of the SGB unit there are a few items to review before placement and mounting of the blending system begins First verify the machine flange dimensions match the SGB flange if the optional pre drilled holes were ordered The SGB can also be equipped with an optional cast throat section with a drain port This will bolt under the bottom plate of the blender Verify that the machine throat is physically capable of supporting the SGB blending system with a full load of material and vacuum loading equipment installed Important While in operation the SGB applies horizonta
83. n the Setup Directory Screen menu 4x Touch this icon and gee o Pree X rA ai enter in the Service ad PARMA Password to access aR Calibration the Sterling Ej Ffar etup Engineering Only i Shier and Dume Setup Directory oF F949 Config 19 Units O E fat work Setup Done You must have logged in on the Inventory Page using the long password 3145348 to gain access to the Sterling Engineering Only screen The screen similar to that shown below should be displayed and use the keystrokes described herein to change or toggle the parameters Metering Test Go back to Setup Directory Page 105 of 118 12 1 2 Factory Setup Menu Available Selections Metering Test Screen This screen is useful in both R amp D and development purposes when testing the metering performance of each feeder The user can perform a Single Meter by Weight to evaluate the mechanical standard deviation of the gate or auger This test meters for the calculated time based off the target weight entered on this screen The blender does not retry or adjust the time of the meter to reach the target but instead always meters for the same amount of time as long as the target weight has not been changed This allows you to open the gate for several feeds using the same amount of time You can then record the Dispensed Grams and plot the standard deviation
84. nder with a full load of material and vacuum loading equipment installed Important While in operation the SGB applies horizontal and vertical pressures to the mounting flange If there is a question as to the mechanical stability of a mounting flange contact Sterling s Mechanical Engineering department Ensure that the gravity feed tube is installed in a vertical position so that the materials will gravity flow to the extruder hopper Use aluminum tubing or smooth wall flex hose GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMER OFC WITH RE LOAD VALVE PURCHASED SEPARATELY AAMAS MAMMARY gt If possible use rigid tubing Some flex hose will tend to sag and generate static that could cause de mixing between the blender and the extruder Make sure that adequate space is around the blender 36 recommended to allow proper cleaning servicing etc N SGB Batch Blender with Mitsubishi Controller Page 39 of 118 wT 4 2 1 3 Floor Mount Central Blender In a floor mounting application ensure adequate clearance for all blender operations and maintenance The operator and maintenance personnel must have access to parts of the blender If necessary it is the customer s responsibility to provide adequate safe work platforms around the blender to meet state and local safety codes Using proper lifting equipment lift the SGB in place Important The blender must be securely fastened to the floor be
85. nting plate las Page 98 of 118 ke SGB Batch Blender with Mitsubishi Controller Technical Assistance Parts Department Call toll free 7am 5pm CST 800 783 7835 or call 262 641 8600 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 783 7835 or call 262 641 8600 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 262 641 8600 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8600 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials
86. o the double slot on top of the gate assembly and secure it in place with the socket head screw that is provided Be sure to use the lock washer to prevent the stroke limiter from coming loose Stroke Limiter N SGB Batch Blender with Mitsubishi Controller Page 77 of 118 Sy Maintenance 6 6 1 Work Rules The installation operation and maintenance of this equipment must follow all applicable work and safety codes for the location where it is used This may include but is not limited to OSHA CSA NEC SPI and other local national and international regulations In addition you must observe the following specific rules K Read and follow these instructions when installing operating and maintaining your equipment If the instructions become damaged or unreadable you can obtain additional copies from the Service Department at Sterling Only qualified people may work on or with this equipment Work only with approved tools and devices Turn off and lock out the power switch when maintaining or servicing your blender system Disconnect and lock out main power before servicing electrical equipment 6 2 Maintaining Blenders Sterling blenders need periodic maintenance to provide long dependable service Check these elements regularly WARNING S Page 78 of 118 e Check functionality of safety circuit daily e Maintain proper air pressure and drain water from trap assembly on regulator a
87. of the gate The other purpose of this screen is to verify that the dispensed weight displayed is correct You can perform a meter and then pull the weigh hopper to weigh the material ona gram scale The value on the screen should match the measurement on the gram scale If it does not then either the weigh hopper is not balanced correctly or the scale calibration is not correct Refer to the Troubleshooting Section of this manual for additional details eter ing Lert Fress to Begi Select a Feeder eee Stop the Meter Target Weight Change Method Meter Data Go back to Sterling Engineering Only Directory Advanced Weight Options Screen This screen allows you to modify the weight filter adjust the mechanical time to settle the weigh hopper after dumping adjust the mechanical time to settle after a feeder has T Page 106 of 118 SGB Batch Blender with Mitsubishi Controller lt Weight Filter Weight Sec Filter Feed Algorithm Options Screen introduced material into the weigh hopper adjust the Maximum Empty Weight of the hopper The weight filter is the specialized filter algorithm that smoothes erroneous load cell readings The signal will be filtered more if this value is increased and less if decreased This setting should not be modified except by the developer except under unusual circumstances Adjust the limit for Hopper Over Max Weight Time to settle hopper after ba
88. oid valve is energized it opens the metering valve cylinder When the solenoid valve is de energized it closes the metering valve cylinder If the power is interrupted to the blender the metering valves will return to the closed position to prevent material from over filling the weigh hopper mix chamber If the blender is in metering mode with one of the slide gates open do not open the front door of the blender The safety switch shuts off the air supply to the blender An open feeder slide gate stays open and an overflow of the weigh hopper can occur SGB Batch Blender with Mitsubishi Controller 1 11 3 Weigh Hopper The weigh hopper on the SGB blender is used to weigh each batch of material and includes an air operated discharge valve After the batch is weighed and the level sensor in the lower mix section is uncovered the valve will open and discharge the batch into the mixer with the existing blended material The discharge valve is also provided with a quick disconnect so the weigh hopper can be removed for cleaning On an SGB blender the weigh hopper rests on each side on a precision cantilever load cell To remove the weigh hopper lift the hopper from the bottom hold the discharge valve closed and slide it out once clear of the locating tab on the bracket above the load cell Once the hopper has been cleaned reposition it onto the load cell brackets using care not to damage the load cells Position the hopper
89. ol Experimentation with this setting can allow the operator to determine the best cycle for the material being weighed 5 8 7 Weigh Hopper Dump Delay Time The dump delay time is the amount of time from the end of metering the last ingredient until the start of the actual dump cycle The start of the dump cycle is marked by the opening of the weigh hopper dump valve This value has a range from 1 second to 999 seconds To view and change the current dump delay time enter the Setup Menu select Mixer N SGB Batch Blender with Mitsubishi Controller Page 61 of 118 wT and Dump Setup screen and then select Dump Delay The default time is factory set at zero seconds This delay time is used to start the mixer prior to dumping the material from the weigh hopper into the mix chamber of the blender 5 8 8 Weigh Hopper Dump Cycle The dump cycle allows the weigh hopper dump valve to cycle or open and close a number of times prior to commencing with the next batch cycle The setting allows from 1 to 9 dump cycles between batches open and closed cycles The normal and default factory setting is 1 meaning the weigh hopper dump valve will open at the end of the weighed batch and close after the batch is discharged into the mixer Setting the dump cycle to more than one cycle may be useful when blending high static dusty material or those that have sticky tendencies This will cycle the dump valve open and closed to allow any
90. otor and the safety switch fails the motor should not be able to run 2 8 4 Safety Device Lock Outs Page 30 of 118 Some safety devices disconnect electrical energy from a circuit The safety devices that are utilized on Sterling SGB models are primarily concerned with the pneumatics and electrical power disconnection and the disabling of moving parts that may need to be accessed during the fas SGB Batch Blender with Mitsubishi Controller normal operation of the machine Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug disconnect plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning any Blend and Reclaim blender including all SGB units Failure to do so may result in serious injury At no time must anyone remove the lockout or reconnect the twist plug other than the person who installed the lockout or who unplugged the twist plug 2 8 5 Lock Outs Plugs and Other Safety Devices The SGB blending system utilizes several types of safety devices The Line Cord Plug This line cord plug allows the operator or maintenance personnel to unplug the blending system from its power source an
91. ource unless you ALARM intentionally killed the power during the batch PLC Battery Low Change out the PLC battery with your spare PLC Module Loaded Check the input power Verify that 110 volts or 220 volts are 10 This voltage must remain constant with all the motors starting and stopping Insure that the blender is on a clean circuit that does not have other equipment on it If the power is known to be intermittent and have problems set up the unit to run in AutoStart mode See the factory setup sheet at the end of this manual In this mode if a short power interruption occurs the blender will automatically restart board Adjust to 5 VDC 0 1 volt Check the display ribbon cable connection to the CPU board and the display See the electrical chapter for more information Check the contrast adjustment located on the display board Check keyboard ribbon cable connections Check the CPU board for lockup To do so reset the CPU board by cycling the power off and on at the motor control panel N SGB Batch Blender with Mitsubishi Controller Page 85 of 118 wT Possible solution Weigh hopper occasionally Check batch weight setting in the recipe menu See the setup chapter for overfills more information Check the ingredient supply hoppers to verify proper ventilation If a vacuum receiver has a leaking flapper valve and the supply hopper is not vented the blender computer can learn inaccurately and
92. out and press OK Verify that the calibration weight is not touching anything other than the load cell bracket Enter the number stamped on the calibration weight Follow the on screen instructions by touching OK and then follow the prompts The blender will evaluate the calibration and indicate if it is properly calibrated Press Done key three 3 times and you will return to the main menu 5 5 2 Standard Calibration on a blender with an HC style mixer Recommended only if calibration is out of spec 1 OF REON Login by touching login from the Inventory Page and enter 5413 then touch the Sterling logo to access setup Touch Calibration and then Scale Calibration Empty the hopper and press OK Place the test weight on the hopper and press OK The controller will communicate whether the calibration was successful 5 5 3 Additional settings that usually do not have to be changed 1 Login by touching login from the Inventory Page and enter 5413 then touch the Sterling logo to access setup NOTE If the controller is set to Continuous Mixing then the 2 Page 52 of 118 blender will run continuously while the blender is operating If it is set to Timed Mixing then the mixer will run for the Mixing Time setting when a batch is dumped into the mixer Touch the Mixer and Dump Setup key to enter the amount of SGB Batch B
93. parts e Shut off power to the blender when it is not in use Turn the switch to the OFF position or unplug it from the power source 2 7 Maintenance Responsibility Safety is essential to the good health of both operator and machine If you are a maintenance worker you must make safety a priority in order to effectively repair and maintain equipment BEFORE REMOVING ADJUSTING OR REPLACING PARTS ON A MACHINE REMEMBER TO DO THE FOLLOWING e BLEED all air pressure from system components refer to the Maintenance Section of this manual e TURN OFF all air and electric supplies and all accessory equipment at the machine e DISCONNECT AND LOCK OUT electrical and pneumatic power and attach warning tags to the disconnect switch and air shutoff valve Lm Page 28 of 118 SGB Batch Blender with Mitsubishi Controller When you need to perform maintenance or repair work on a blender above floor level use a Solid platform or a hydraulic elevator If there is a permanently installed catwalk on your blender use it The work platform should have secure footing and a place for tools and parts DO NOT climb on blenders machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable
94. pe Book icon located on the Recipe Screen 2 Select a stored recipe by changing the number next to Recipe 3 Touch Load and then Done this takes you back to the Recipe Screen 4 Touch Accept New Recipe to accept the loaded recipe into the blender Note If replacing the current recipe with one that is downloaded from the Recipe Book make sure that the previous recipe has been saved as it will be overwritten by the new downloaded recipe 5 8 19 3 Display Recipe Contents The display recipe function is used to verify the contents of a recipe number before it is loaded from the recipe book In order to view the desired recipe the operator must enter the number which contains the recipe he wishes to view Once a valid recipe number is entered the display will indicate the contents of the stored recipe in percentages 5 8 19 4 Erase Recipe or Entire Book The Erase Recipe or Entire Book function is used to eliminate old or outdated recipes from the recipe book If the operator only wants to delete one recipe the configuration for that recipe should be currently displayed on the screen The controller will only prompt the operator if they want to erase the entire book when that key is pressed Once a recipe number is deleted the contents of that recipe are lost The recipe number may be used again in the future for new recipes N SGB Batch Blender with Mitsubishi Controller Page 75 of 118 wT 5
95. pe Page 5 8 19 1 Save Running Recipe to the Book Page 74 of 118 The save current recipe to book function allows the operator to save the contents of the current recipe to the recipe book under a desired number Upon selecting this function the operator will be prompted for a reference recipe number This may be any number from 1 to 50 The assigned recipe number will be used for all further references to this recipe until deleted The operator should be familiar with the recipe numbers used We suggest keeping a loose leaf notebook with 50 tabbed pages as a reference to what is kept in the blender so this can be the standard for all blenders in the plant etc To save a running recipe to the Recipe Book perform the following steps 1 Enter the Recipe Book by touching the Recipe Book icon located on the Recipe Screen 2 Select a stored recipe by changing the number next to Recipe 3 Touch Save Running Recipe and then Done la SGB Batch Blender with Mitsubishi Controller 5 8 19 2 Load a Saved Recipe from the Book The load from book function allows the operator to retrieve a previously stored recipe from the recipe book and install it into the current recipe menu This will overwrite the current recipe so make sure that it has been saved to the book before installing a new recipe in its place To load a previously stored recipe from the Recipe Book 1 Enter the Recipe Book by touching the Reci
96. pe Page Start Setup fa Page 68 of 118 SGB Batch Blender with Mitsubishi Controller e Recipe Book Page e Recipe Format Upon Start Up the blender controller will default to the Recipe Menu screen The Recipe Book screen can be accessed in the Recipe Page and is useful in storing and retrieving recipes The Recipe format option can be accessed in the Setup screen and is used to select one of three available formats Quick Set Percentage Mode or Parts Mode Quick Set is the default setting preset at the factory In addition every feeder in the blending system does not need to have values entered Percentage or Parts recipe formats or a material type REGRIND NATURAL or ADDITIVE in Quick Set recipe format Recipe Format Menu e Quick Set Percentage or Parts Batch Size Inventory Shutdown Batch ready mode e Auto start mode 5 8 15 Current Recipe Menu Throughout the menu structure the top left corner of the display will list the name of the current screen that you are in Each individual button will indicate instructions for keystrokes In the Recipe Format menu shown on the previous page pressing on the mode button displayed at the top of the screen will show the Current Recipe menu Note The blender will always run the percentages shown in the Current Recipe menu display 5 8 16 Quick Set Menu The Quick Set menu structure allows reci
97. pes to be entered and adjusted by touching the buttons on the panel face for 1 to 6 components This is convenient for use in the injection molding industry After an Quick Set is selected the screen will display the label on the Recipe screen The first component 1 material hopper on the blender is always designated NAT for natural virgin and cannot be changed The other ingredient labels can be scrolled by pressing the hopper number They N SGB Batch Blender with Mitsubishi Controller Page 69 of 118 wT can be scrolled to read NAT natural RGD regrind or ADD additive The selected label will be displayed for the ingredient hopper with an arrow next to the abbreviation Component 3 is designed to handle regrind and most models come equipped with a larger square gate to reduce the likelihood of bridging If regrind is being used it should always be run through component 3 If you don t have regrind another major ingredient can be run through component 3 The ingredient labels names selected will be displayed on the recipe menu so the operators will know what material is being blended The natural or virgin component 1 ingredient will not be shown on the recipe menu If additive is designated the weighed ingredient will be metered as a percentage of the natural or virgin If regrind is designated component 3 the ingredient will be metered as a percentage of the total bat
98. production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the blender and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment ONLY YOU can make safety work for you by constantly thinking about what is safe and what is not It is often the just once that an operator reaches into a blender to remove material and it results in serious injury Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the blender without appropriate training and first reading and understanding this manual e NEVER try to pull m
99. rget vs actual data units Ibs or kgs Alarm Log View and clear the alarm log Alarm Setup Stop Continue when out of material Alarm No Alarm when out of material Alarm Silence delay User Interface Lock Lock the user interface to prevent others from making changes or viewing your blender Be sure to logout after locking ke SGB Batch Blender with Mitsubishi Controller 6 5 Mechanical The mechanical design of the blender is very simple and very little maintenance is required The only moving parts are the metering gates weigh hopper dump valve and mixer agitator The following maintenance is suggested Daily e Inspect blender for any loose parts tighten them immediately e Verify quality of compressed air supply e Verify mixer door is properly latched Weekly e Inspect metering gates for proper operation Monthy e Inspect air regulator and air safety circuits if equipped e Recalibrate blender only if necessary Typical Model SGB Assembly Overview JA SGB Batch Blender with Mitsubishi Controller Page 81 of 118 Sy 6 6 Electrical 6 6 1 Description and Objectives This section is designed to give the operator an overview of the electrical system that controls the SGB blending system Since the SGB s control panel is a self contained pluggable item seldom will a maintenance person be required to enter the control panel For purposes of understanding the system it is advisabl
100. s is highly sensitive to oily dirty wet or contaminated air If oil dirt water or any other air borne contaminates enter the system the components could be damaged and injury to the operator could result A proper air supply must be supplied to the blender When the safety circuit is disabled the air pressure to the cylinder will drop off by shutting off all the air supply to the valve stack with the pilot operated master air valve This will also cause the weigh hopper discharge door to open lax Page 18 of 118 gt SGB Batch Blender with Mitsubishi Controller 1 11 5 Mix Chamber All of the Sterling batch blenders are equipped with an integral mix chamber The mix chamber holds multiple batches of material so any variations in a batch are averaged over time 1 11 5 1 Opti Mixer The Opti mixer is designed to provide bi directional mixing action and can be easily taken apart for cleaning This design is standard on all SGB blenders 1 11 5 2 HC Mixer The HC Mixer features an open wheel design and is best used for multiple regrind materials and rigid pellets It is optional on all SGB models WARNING Never reach into the mix section of the blender without disconnecting the power or air supply Serious injury can result from getting your hand caught in the rotating mixer 1 11 6 Operator Control Panel The operator control panel includes a 8 foot 2 4 m cable and can be remote mounted not re
101. s important that the air pressure to the blender is not fluctuating by installing the unit on an air line with other equipment using large volumes of air If this is the case an accumulator tank with a check valve may have to be provided by the customer to ensure the blender a steady air supply WARNING Always disconnect the compressed air supply when working on any part of the blender fax Page 84 of 118 ke SGB Batch Blender with Mitsubishi Controller 7 Troubleshooting 7 1 Description and Objectives This section provides basic troubleshooting procedures to common SGB blending system problems Any problem encountered that is not listed should be discussed with an Sterling service technician Possible solution Nothing happens when Check to make sure that air is hooked up and the regulator gauge reads push Start Blender at precisely 60 PSI Check that the access door to the mixer is shut properly Look on the Recipe Screen If you see Mixer Full then check the mixer If the mixer is not full then check that the mixer prox is adjusted properly small screw on back E STOP has been Check the E Stop located on the front of the blender panel Activated is shown Interface has been Click Unlock and enter in your User Password Locked is shown I ve forgotten my User Contact Sterling s Service Department Password POWER INTERRUPTION Power was lost during a batch Check your power s
102. s required e Periodically lubricate slide gate rails Always remove plug and disconnect power before servicing blender Always read operating manual before operating or servicing blender N ke SGB Batch Blender with Mitsubishi Controller 6 3 SS Sy Controller Setup This section describes the proper setup of the SGB blending system control parameters These parameters are operator changeable however these items should only require setup during the initial installation Only authorized personnel should change them For security reasons the menu that is used to access these parameters is password protected Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the SGB setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage A complete listing of all default values is provided at the end of this manual SGB Batch Blender with Mitsubishi Controller Page 79 of 118 6 4 SGB Series Blender Menu Structure Recipe Page Recipe Book Page Start Save the running recipe to the Recipe Format Percentage Parts or Quick gt Change Recipe Values by book Set touching the number you wish to change Touch Accept New Recipe button after you ve made the desired changes Start or stop the blender by to
103. s set to 1 then the batch will dump normally 8 Press the number next to sec on the Mixer Dump Time to enter the amount of time that the mixer will run while dumping material out of the knife gate below the mixer This feature assists in cleaning out the mixer 9 Press Done to return to the Setup screen 10 Press Alarm Setup on the Setup screen to look at the Alarm Flags amp Feeder Setup screen 11 This screen allows you to change the way alarms on each feeder function Enter the feeder you wish to configure by pressing the corresponding feeder number under Select Feeder You can select Stop if Out of Material which means if there is any kind of alarm on this feeder the blender process will stop i e The feeder supply hopper is out of material You can also set it to Continue if Out of Material This mode will alarm but let the blender continue to operate or you can set it to No Alarm on Out of Material mode No Alarm mode does not set off any alarms In addition an Out of Material Alarm Silence Delay specifies the amount of time before an alarm will be set off 12 Press Done to return to the Setup screen N SGB Batch Blender with Mitsubishi Controller Page 53 of 118 wT 5 5 4 Verifying Calibration Recommended on a periodic basis to ensure accuracy 1 Login by touching login from the Inventory Page and enter 541
104. sconnect the compressed air supply when working on any part of the blender 4 7 Blender Set up 4 7 1 Description and Objectives This section will discuss the mechanical setup and control system setup of the SGB blending system After reading this section you should be familiar with the mechanical setup and the electronic control setup of the 4 _ SGB Batch Blender with Mitsubishi Controller Page 43 of 118 Sy SGB blending system 4 7 2 Weigh Hopper Installation Remove the weigh hopper from the shipping box and install it in the blender on the load cell brackets Connect the airline and close the mixer door securing the latch 4 7 3 Load Cell Adjustment The mechanical setup of the SGB blending system involves the adjustment of the weigh hopper load cells Please refer to the figure on the next page This figure illustrates the proper adjustment of the load cell mechanical stop bolt The setting for the positive stop is necessary to prevent the load cell from being over ranged by excessive loading on the weigh hopper The setting for the load cell stop is forty thousandths of an inch maximum 040 A feeler thickness gauge with the weigh hopper empty should be used to set this If a feeler gauge is not available the weigh hopper should be filled with the material that is to be blended and the stop adjusted so there is just a very small gap a couple of sheets of notebook paper between the load cell and the blen
105. scription 91 10 Tech ical Assistance einh a E E 99 10 1 Contact Information for Technical Assistance ccccseeeeee 99 10 2 Returned Material Policy cccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 100 10 3 MaA N e a atacand ere cert careers aes 101 11 Safety Tag Information iAverceencessveviecwcteduanuvieaetereataatesaeneecadids teicieyuves 102 11 1 SGB Blender Safety Tags 1 2 scceseceseceseseeeceseneecceeeneeepeneteneneces 102 11 2 Pushbutton and Touchscreen Tags 103 11 3 Blender Identification Serial Number Tag ceeeeeeeee 104 12 APPENA tocincseateu e bene thtnes a E E mess laces 105 12 1 Addendum Service Supervisor Information eeee 105 12 2 Passwords irene manen a a a 112 12 3 Default Values factory defaults shown cee eeeeeeeeeeeeeeeeeee 112 la Page 4 of 118 SGB Batch Blender with Mitsubishi Controller Safety Considerations Sterling equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M M M Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the blender Use car
106. shows the last 100 stored alarms The log Log can be viewed and cleared MM OD YY 1H MM 55 PM HOPPER 6 Low Level Alarm Log Go back to BS Setup Directory Clear Alarm Log Scroll Through Alarm Log Ay Programmable Features continued After all selections are made e Keep pressing the Done key until the unit returns to the Recipe menu Important Programmable features should not be accessed by Page 110 of 118 Controller inexperienced operators or inexperienced plant personnel Unauthorized changes may prevent the blender from operating properly and may void part or all of the warranty Call the Sterling Service Department for assistance or for further explanation of these or any other programmable features which may or may not be shown in this manual T ked SGB Batch Blender with Mitsubishi Information included in this manual is subject to change without notice Remember Blender controller default password is 5413 Service Notes N SGB Batch Blender with Mitsubishi Controller Page 111 of 118 wT 12 2 Passwords User Password 5413 Maintenance Password 3145348 CAUTION Maintenance password should only be supplied to qualified personnel The program can be compromised 12 3 Default Values factory defaults shown SGB BLENDER CONFIGURATION PARAMETERS Recipe Entry Mode Batch Size nventory Shutdown SSCS Enabled utoStart Mode
107. supplied alarm device as described above The alarm contact has a maximum load of 3 amps N SGB Batch Blender with Mitsubishi Controller Page 83 of 118 6 7 Pneumatic System Maintenance The SGB blending system uses plant supplied compressed air to operate the metering and dump valves on the blender It is the user s responsibility to provide CLEAN AND DRY air for the blender to be connected to The air supply should be filtered through a 5 micron air filter and have a water separator installed Oil should not be used unless air dryers are installed on the compressed air supply In this case an oiler may be required on the blender to keep the air cylinder seals lubricated Important As this blender uses air for blender metering functions it is very important to supply clean dry air to the blender Dirty air can affect blender accuracy result in poor performance and cause injury Provide a 5 micron air filter on the air supply to the blender and be sure excess oil is removed DRY 60 psi COMPRESSED AR oreo CUSTOMER SUPPLIED COMPRESSED AIR COMPONENTS SGB BLENDER Sterling provides all pneumatic lines on the blender piped to a single 4 NPT standard pipe thread fitting The SGB blending system requires approximately 1 cfm 60 psi 1 7 m hr 4 14 bar air pressure for proper operation The working pressure of the blender cylinders is 60 psi This is adjustable by the regulator supplied on the rear panel of the blender It i
108. tch has dumped Adjust Settle Time Hopper Weight Hin HHH Lbs Go back to Sterling Engineering Only Directory This screen allows the user to configure how the blender metering algorithm works The user can adjust the Initial percentage of Target to Meter the Allowed Underfeed value the number of retries before Double Gate Time the allowed Weight Sec Drop and the Out of Material retry limit Hopi Hop Hops Hope Hopo Hope HHHH Lbs HHHH Lbs oS Batches for Ht Go back to Sterling HHHH Lbs Cate Engineering Only HHH Lbs Eu Directory HHH Lbs Done 7 N SGB Batch Blender with Mitsubishi Controller Page 107 of 118 wT Feed Calibration Options Screen This screen allows you to perform the feeder calibrations for each feeder in weight per second This is useful when the feed calibration is giving you an error message most commonly caused by overfilling the hopper during the calibration Select a feeder and then follow instructions An error is shown if the current feeder calibration feed time was too short the feed time was too long or if the hopper weight exceeded 110 of the set batch weight In the case that the feeder exceeded 110 maximum hopper weight due to a high rate hopper then the Batch for Feeder Cal setting might be set too high Consult Sterling if this problem arises The current feeder calibration values are also show
109. the operator touchscreen input The mix hopper high level signal is generated by a proximity level sensor located in the right hand portion of the mixer chamber viewing from the mixer door Load cells require 10 volts DC to operate This is known as the load cell s excitation voltage SGB Batch Blender with Mitsubishi Controller 6 6 4 Output Signals from Programmable Controller wT The SGB blending system uses several output control signals to control the process All of these are very similar in nature the first of which is the mixer motor control The mixer motor is controlled by a PLC output The weigh hopper dump valve output functions similar to the mix motor output Please refer back to the wiring diagram The origin of the weigh hopper dump signal is a PLC output Each SGB blending system includes an auxiliary customer alarm output This dry contact can be used to switch a remote alarm signal The customer alarm output is provided to actuate or energize a variety of alarm horns buzzers strobe lights and beacons These are normally provided by the customer and care will have to be exercised not to exceed the maximum current draw 3 amp maximum The contacts will close whenever the control detects a fault that will somehow inhibit the blending system from properly blending the material Note The customer alarm contact is open if the panel control power is turned off This contact is for use with a customer
110. this doesn t fix it then to re occur manually perform feeder calibrations and retest dumps an incorrect the components incomplete size are set properly Check the status of the alarm flags amp Feeder Setup to ensure that all of the feeders are set to Retry In addition if the blender is configured for timed batches then this can cause error Check supply hopper ventilation to prevent problem associated with leaky vacuum receiver flappers Blender keeps dumping Check the mixer high level switch sensitivity When the sensor is covered after mixer is full by material the indicator lamp on the back of the switch should be lit To adjust the sensitivity use the small adjustment screwdriver that was provided with the blender The adjustment pot is located on the back of the sensor Rotate clockwise to increase the sensitivity less material in front of the switch to actuate it Rotate counter clockwise to decrease the sensitivity more material covering the switch Blender will not batch with Check the mixer high level switch sensitivity Fines may have coated the empty mixer level switch it needs readjustment Check the proximity switch connection Make sure that the recipe is correct Check batch size las Page 86 of 118 SGB Batch Blender with Mitsubishi Controller Possible solution Mixer won t shut off and Check the Mixer and Dump Setup to see if the mixer is configured for runs continuously Continuous Mixing
111. tion is described below and is determined by the position of the knife gate switch located on the side of the back control panel Mixer Slide Gate Switch Positions AUTO Slide gate functions are automatically controlled by the blender controller OPEN Slide gate open all the time CLOSE Slide gate closed all the time TYPICAL CENTRAL BLENDER LAYOUT SGB Batch Blender with Mitsubishi Controller Page 23 of 118 Pneumatic Slide Gate Below Mixer _ Take off Compartment a a SS Floor Stand Surge Bin Safety 2 2 1 Work Rules Install operate and maintain this equipment according to applicable work and safety codes for your location This includes OSHA CE NEC CSA SPI and many other local national and international regulations Obey these specific work rules Read and follow the instructions in this manual before installing operating or maintaining any equipment Additional copies are available from Sterling Only qualified persons should work on or with this equipment Work only with approved tools and devices Disconnect and lock out power while working on this equipment Page 24 of 118 SGB Batch Blender with Mitsubishi Controller 2 2 Tools and Equipment Needed You ll need the following e Hand tools e Fork lift or overhead lift e Wire conduit and fittings for wiring runs if receptacle is not already in place e Mounting bolts with nuts and washers e Compressed air tubing an
112. uching the Push to Start or Stop button Access Recipe Book Page Access Clean Out Page Access Inventory Page Access Setup Page Page 80 of 118 Delete a stored recipe Load a stored recipe Erase all stored recipes Modify the product ID for a stored recipe Return to the Recipe page Clean Out Page Empty the blender hopper s Manually Operate the mixer weigh hopper dump gate and the slide gate below the mixer View and test all inputs and outputs on the blender Return to the Recipe Page Inventory Page View the accumulated inventories View batch time View blenders maximum capacity View the average process rate Return to the Recipe Page Setup Page gt Login from the inventory page by hitting Login and entering in your password Then access setup by touching the Sterling Logo la VVVVVVV Batch Size Inventory Shutdown Batch ready mode Auto start mode Report Setup Blender Number Auto clear option Auto interval setup Auto start time Calibration Scale Calibration Direct Scale Readout Feeder Calibration Mixer and Dump Setup Mixing Time Remix Time Dump Time Dump Delay Dump Cycles Mixer Dump Time Timed Continuous Mixing Option F940 Config View software version Access F940 Config setup to modify time settings Units gt Blender data units Ibs or kgs gt Ta
113. y performing the following steps e Touch the Recipe Book icon located on the Recipe Screen e Select a stored recipe by changing the number next to Recipe e Touch Load and then Done This will take you back to the Recipe Screen e Touch Accept New Recipe to accept the loaded recipe into the blender To Save a running recipe to the Recipe Book e Go to the Recipe Book by touching the Recipe Book icon located on the Recipe Page e Select a stored recipe by changing the number next to Recipe e Touch Save Running Recipe and then Done 5 Press Push to Start or Stop button to start blender 5 3 Recipe Entry Formats The Recipe Format screen allows the user to change many parameters concerning the way that the recipe is entered by the operator It is accessed by touching the Sterling icon on either the Recipe screen or the Inventory Screen The user must enter in the User Password to gain access see User Password Setup for details The following Recipe Modes are described below 5 3 1 Quick Set Most common in injection molding In this mode hopper 1 is configured as virgin hopper 3 is configured as regrind and the others are configured as additives i e color The operator enters in the percentage of regrind and additives and the virgin percentage is automatically calculated The regrind percentage represents a percentage of the total batch and the additives are b

Sterling Blender A0567659 User's Manual

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