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Sterling Allen-Bradley 060 User's Manual

1. Continuous Loss in Weight Blenders with Allen Bradley SLC 5 04 Programmable Controller and PanelView 600 Touch Screen Interface Part Number 882 092698 00 Bulletin Number BF3 615 Effective 9 1 08 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2008 All rights reserved Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage 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 the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment 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 before the transportation company s inspection and authorization File a claim with 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 p
2. 5 pm CST 800 423 3183 or call 262 641 8610 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 8 am 5 pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5 pm CST call 847 439 5655 We have a qualified Service Department ready to help Service contracts are also available for most of our products See www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8 am 5 pm 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 Contracting Department Call 262 641 8610 Monday Friday 8 am 5 pm CST Let us install your system The Contracting Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations Continuous Loss in Weight Blenders Chapter 6 Appendix 63
3. Load cell over max Extruder Flow Alarm Blender cannot keep up Pop ups enabled 50 Setting a Recipe To set a recipe touch the hopper you want to change a keypad will pop up enter the desired percentage for the hopper ACS SS 9 a DO Blender Stopped Blending Range MF HH HH HHHH H TO HEHE H Extruder Blender Push to RPM 2953 MF Extruder Kas Hr PERDE Stop Clean Out Touching the Clean Out button will take you to the page to manually run the motors Continuous Loss in Weight Blenders Chapter 4 Operation 51 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The mechanical design of the blender is simple and little maintenance is required The only moving parts are the re fill valves optional regrind agitators metering augers and optional discharge slide gates The checklist below contains a list of items which should be inspected and or replaced to keep your blender operating at peak efficiency Perform each inspection at the regular intervals listed below Figure 52 Sample Preventative Maintenance Schedule System model Dail Date Date Date Date Date Date Date Date Date Date Date any By By By By By By By By By By By Date Date By By Inspect all hoppers for any loose parts tighten them immediately Verify quality of compressed air supply Inspect all weigh hoppers for obstructions
4. very large auger that you are trying to run at a low feed rate This will help to keep the auger from making rapid adjustments Re fill Percentage This is the level the hopper will go down to before re filling Learn Percentage This is the size of the snapshot previously mentioned Increasing this gives you better stability with materials that very in bulk density or do not flow consistently Decreasing this gives you faster updates on the FIFO page for materials that are relatively uniform Summary When adjusting the above parameters you will want to look at the FIFO page and analyze the information given You should be able to determine from the percent deviation what changes to make For example if an additive takes a long time to give a steady flag you may want to lower the Feed Factor Filter or Lower the learn percentage When making changes do make them one at a time and observe the FIFO page for results Another common example is you are running regrind through a feeder and your not getting a steady flag because your percent deviation is too high You may want to increase the Steady Feed Factor or you could increase the Learn Percentage A larger Learn Percentage is usually more stable than a small percentage Continuous Loss in Weight Blenders Chapter 6 Appendix 58 Advance PID Options mass flow setup ADVANCED PID OPTIONS PIO Timer secs PID Gain PIO Integral Constant Sample Time once in Steady Window for FI
5. ENEE 12 HEET 12 CUSIOIIET SOL VIOB Eegeregie 12 2 3 Typical features amp components ceret ee e eed esed ENEE 13 Mechanical features ep Lx uomo DR otis 13 Controller JOGIDEBS at Sais sae eas dens ettam eser orden app deans Ee ker desta 13 ee 13 Blender system component description 14 n MES UI PH EP EM 19 2 5 Safety devices and Wee EE 20 CHAPTER 3 INSTALLATION eee 22 St Uncraung the eq ipmen erensia peer ret t e Eege edu EEN etna E 22 3 2 Rigging and placing the ib sicco ire repo errare ria sini Gen Dei Re due 22 Site reguliremenls ete te hee eae e aaa Hes vu de Ep eese habe AEE SES 23 Mounting configuration ple 23 SN ele e e EE 26 3 4 PneumaucinstallauUOEy 5 e ete ete Le ofer ti er decer into i ortho bids 27 3 5 Overall installation SUrmltfiary s sos teet ioo terae reges dee Dt eos et ege 28 Ce MN LEE 29 Load cell adjustment EE 29 Final COMMC CHONG een ee ee eege eege 30 Controller Set Ds oclo hea aia teh nh a hia E ool dias aiebant o Tua dU 31 Scale calibrati n elt CPC 31 TM 44 CHAPTER 4 OPEHATIONL cnin tens cou Uo aono c coe Seege eon konnen 47 4d eStat V cT E 47 General oDerallOR ec o ert or ee a ERERE RET in t E URL n D D Rep EE 47 4 2 Controller description amp operation eee cece cece eter eset eeeeeeeeeeeeeeeeeeeeaaeeeeeteaaeeeeeae 49 Display description eR MEE 49 SOIUDO Ee 51 Continuous Loss in Weight Blenders iv MAINTENANCE vince sini t
6. PSI Note Ensure that the compressed air is regulated to 60 PSI max Continuous Loss in Weight Blenders Chapter 3 Installation 28 3 6 Set up This section will discuss the mechanical setup and control system setup of the continuous loss in weight blending system After reading this section you should be familiar with the mechanical setup and the electronic control setup of the blending system Load Cell Adjustment The mechanical setup of the continuous loss in weight blending system involves the adjustment of the weigh hopper load cells Please refer to the figure below 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 This should be set by a feeler thickness gauge with the weigh hopper empty 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 blender 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
7. assembly on the load cell This is also known as the zero weight point starting point of the scale This zero or starting point must be initialized with an empty weigh hopper There must be no binding or leverage put on the load cell The second weight point that will be used in the load cell calibration procedure is a known amount of weight for the weigh hopper Provided with the blending system is a calibration weight The calibration weight is stamped with its actual weight on top If this is not available any object with a known accurate weight to the nearest 1 100 of a Ib in the 5 10 Ib range Continuous Loss in Weight Blenders Chapter 3 Installation 31 will suffice The weight will be in pounds unless the blender is provided for metric display operation kilograms Given the two weight points on the load cell scale the controller will be able to determine any other weight on the load cell span This is limited to the maximum capacity of the load cell The standard load cell used on these blenders have a span accuracy of 1 10 The maximum capacity of each load cell is clearly marked on the fixed top of the load cell This value will be indicated in kgs 2 2 lbs 1 kg Figure 11 Blender Calibration Weight 6 14 LBS Scale Calibration During the initial setup of the blenders the feeder units will need to be setup Most of these items should have been setup at the factory before the unit shipped To calibrate the
8. be HHHHH HHHHH HHH HHHHH in LBS 1 nii IT HHHH bits 2i HHH HHH HHHHHH bits 3 HHH HHH HHHHHH bits 4 HHH HH HHHHHH bits SHH HHE HHHHHH bits G HHE HE iiHHHHE bits mE HHE HHE HHHHHH bits dispensed into the Mass Flow hopper during this procedure Continuous Loss in Weight Blenders Chapter 3 Installation 34 Touch the ACS Group Logo Then enter password 5413 ACS gu io im ium LT eee are aie eae ULLA ULL 1 2 3 4 Blender Stopped MF Gan eH DE xtruder RPM Touch the OK button Touch the Calibration button Hopper Setup Hopper Setup Calibration Panel View Config User Password um FIFO DIAGNOSTICS Continuous Loss in Weight Blenders Chapter 3 Installation Touch Feeder button Feeder Calibration is carried out as follows 1 Select the feeder you want to calibrate and enter the value in Feeder by touching the adjacent box Determine the calibration weight and enter it in the box for Cal Wt This should be about 10 of the hopper size Enter the Calibration speed by touching the box adjacent to Cal Spd This should be 60 Touch the Press Here to Begin Box The selected feeder will now start dispensing resin until it reaches the calibration weight entered above Pressing Abort will stop the calibration if you have a problem Repeat this process for all feeders It is possible to for
9. is not in use Turn the switch to the OFF position or unplug it from the power source Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch 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 around your blender use it The work platform should have secure footing and a place for tools and parts DO NOT climb on unit 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 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 are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you ha
10. the gap Note THE WEIGH HOPPER ASSEMBLY MUST BE FREE FROM FRICTION WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF Figure 10 Load Cell Mechanical Stop Adjustment Weigh Hopper L E Load Cell amp Hl it Blender Frame O4o Continuous Loss in Weight Blenders Chapter 3 Installation 29 Final Connections 1 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 Note 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 Note Make sure that the blender is supplied with clean dry 60 psi 4 14 bar compressed air Continuous Loss in Weight Blenders Chapter 3 Installation 30 Controller Setup This section describes the proper setup of the continuous loss in weight 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
11. then be removed and the colors changed without the processing machine having to be re strung and the product having to be re gauged Continuous Loss in Weight Blenders Chapter 2 Functional Description 18 2 4 Options The following is a list of options which your blender may have been equipped with e Mezzanine stand with slide gate and 4 tube stub e Low level proximity switches Detects material supply shortages for each supply hopper before blender runs out Requires a separate remote mount alarm panel with its own lights horn and silence button e Supply hopper lids for non ACS supplied vacuum receivers amp loaders e Agitated straight wall regrind supply amp weigh hoppers for regrind material e Compressed air loader for low percentage additives e Ethernet communication module Remote Display Allows control of blender from a second location up to 50 feet 15 meters away The remote display can be located in another location to allow the blender to be operated from that position The additional remote PanelView 600 operates identically to the main display Continuous Loss in Weight Blenders Chapter 2 Functional Description 19 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the continuous loss in weight blender This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contain
12. Date Date Date Date Date Date Date Date Date Date Date Every week Sy Verify the blender is properly calibrated Check to make sure that all hose connections are air tight Date Date By By Inspect air regulator and air safety circuits if equipped Recalibrate If necessary Photocopy this page for your maintenance records Continuous Loss in Weight Blenders Chapter 5 Maintenance 52 Note Other service problems or questions can be answered by contacting the Service Department Continuous Loss in Weight Blenders Chapter 5 Maintenance 53 Chapter 6 6 1 Appendix Spare Parts Typical Blender Parts List DESCRIPTION 015 060 100 1 Lid 0 2 to 1 6 cu ft vacuum receivers 08223 1 08278A 08412 1 Lid 3 0 and 6 0 cu ft vacuum receivers N A N A A0770325 2 1 8 NPT fitting 35085K and 35086K 3 1 4 NPT fitting 35154 and 35155 4 Bulkhead 35146 5 Brass elbow 35118 6 24V DC Solenoid 33128 7 Dump cone 15370 15237 8 Air cylinder 33126 33073 33011G Typical Weigh Hopper Assembly Parts List 7 kgs 10 kgs 15 kgs 30 kgs 150 kgs ais 724 00835 00 724 00836 00 724 00832 00 724 00839 00 61 1250 150KG Figure 64 Typical Allen Bradley Controller Main Parts List Description ALL MODELS 1 Allen Bradley SLC 500 CPU A0555198 2 24 VDC pow
13. FO This is how often the control takes snap shots of the mass flow hopper and enters the number in the FIFO table For quicker FIFO updates you would decrease this number For a more stable process you would increase this number Steady System Limit This is the allowable percent deviation around the median The median will be half way between the re fill set point and the hopper size set point For material that varies in bulk density or does not flow consistently you may have to increase the limit Steady System Time Test This timer is used to determine whether or not to show the Steady System flag on the main control screen Rather than going in and out of stable the process must remain stable for the set time and then the Steady System will be shown PID Timer This is the amount of time that the blender will run without making a change to the auger speeds to adjust the blender though put i e pounds per hour PID Gain The gain increase or decreases the size and speed of the adjustments made to the PID A smaller number makes slower adjustments A bigger number makes faster adjustments Continuous Loss in Weight Blenders Chapter 6 Appendix 59 PID Integral Constant Works the same as the Gain Feeder Speed Limits SPEED LIMIT OPTIONS This allows you to set the minimum and maximum speed for the motor drives as a percentage The drives are not supposed to be run at less than 8 hertz and should not be run above 115
14. MAMNLIAL OPERATION MASS FLOW WEIGH HOPPER LOAD CELL FLOW GUT TO PROCESS Note The lower or common mass flow weigh hopper uses the change in weight over time of material contained in the hopper over time to calculate it s discharge rate differential rate This learned discharge rate is then summed with the known total metering rates of the blender feeders to learn the actual processing rate of the processing machine The blender output rate is then adjusted to match the learned processing rate eliminating the need for a blender mixer Fixed Rate mode The lower mass flow weigh hopper may be replaced by a collection hopper with high and low level switches on higher capacity blenders This configuration controls the blending system rate based on material level rather than material weight DH Continuous Loss in Weight Blenders Chapter 2 Functional Description 17 PLC Control Panel The PLC control panel may be mounted on the side of the blender frame or remote mounted near the blender It uses an Allen Bradley SLC 5 04 programmable controller with standard 24 vdc input output cards This design provides excellent blender performance along with easily replaceable off the shelf parts in case of any electronic component failure Touch Screen Interface The Panel View 600 color touch screen display can be mounted up to 50 feet 15 m from the PLC control panel It is very user friendly after installation and setup simply e
15. access to all 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 For specific dimensions refer to the assembly diagram provided with each blender Note Auger assemblies require a minimum of 24 inches of clearance for proper servicing and cleaning Insure the chosen location for the blending system is adequately away from high traffic aisles Insure that normal day to day operations will not place the blending system at risk of damage Once a proper location has been chosen securely fasten the blender floor stand frame to the floor Note The blending system MUST BE SECURELY LAGGED TO THE FLOOR before operating the unit The floor mounted version has a blower and venturi that continually conveys the metered blend to the processing machine mounted mass flow weigh hopper The blower unit can be placed in any position around the venturi and connected with a flexible hose It is provided for a straight hook up from the factory but this can easily be field changed to any convenient location with additional tubing and a longer wiring conduit These blenders have been installed with the blower remote from the blender and connected with rigid aluminum tubing bends and Morris couplers This is the customer s preference All conveying tubing is to be provided by the customer and is not included with the blender pricing If the r
16. ags are available at most electrical supply stores Amphenol quick connect Plug Connected to Each Auger Motor The plug must be unlatched and the female end of the cord removed from the motor plug This disables the motor from turning while the auger unit is being serviced or cleaned The motor cords are cut to length so they must be disconnected before the auger can be removed from the housing Note Disconnect both of the items listed above before cleaning or servicing equipment Figure 5 Plug Motor Caution Disconnect the electrical power and compressed air source before working on the equipment Continuous Loss in Weight Blenders Chapter 2 Functional Description 21 Chapter 3 Installation 3 1 Uncrating the Equipment Continuous loss in weight blenders are shipped bolted on a skid enclosed in plastic wrap and contained in a wood crate 1 Remove the crate from around blender 2 Secure strap of proper lifting capacity to the lifting lugs installed in the holes provided Caution Use approved safety straps or chains to lift the blender from the eyebolts on Q the top plate See figure 6 below for eyebolt positioning Figure 6 Lifting Eyebolt Position on Blender Lifting Eyebolts Caution Remove hoppers if necessary to prevent damage 3 Lift blender until strap is taut 4 Remove bolts attaching bottom of blender to shipping skid 5 Raise the blender slowly 3 2 Rigging and Placing the Unit It i
17. are not controlled nor read by the blender Their existence is solely for the use of a low level alarm to be wired into a separate controller These would not be present on a standard blender The hoppers may be equipped with a polycarbonate sight glass This is mounted in the upper cone section of the hopper This is useful for a quick reference of the material level in each hopper The supply re fill hoppers should be vented to the atmosphere through the louver located on the lid of each hopper This louver is required to prevent the loading system from creating a vacuum in the hopper which would prevent material from flowing out properly This situation could be caused by a leaking discharge seal on the vacuum receiver Ingredient Weigh Hoppers Each ingredient weigh hopper assembly consists of a conical mass flow weigh hopper a precision load cell and a discharge tube disc seal A mass flow weigh hopper is a steep degree conical hopper with vertical side walls with a discharge tube on the bottom Each weigh hopper is sized to the blender ingredient metering requirements This assembly is responsible for weighing the material ingredients as they are metered out by the metering auger assemblies located below each weigh hopper The manufacturer believes this is the best way to weigh free flowing pelletized materials This design allows the hopper to weigh only the material and nothing else unlike other systems that weigh the heavy auger assemblie
18. at the factory and do not need to be changed However this section of the manual will address all of the blender 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 The following parameters will be discussed Y Changing Recipes e Service e View Recipe e ACS Only e Change Recipe Y Units e Recipe Book e Metric or Standard v Hopper Setup v FIFO Diagnostics e Set Hopper Size e Mass Flow Y Calibration e Feeder e Scale Hoppers Y Network Information e Feeder Y Alarm log v Password v Alarm Setup e User Scale Calibration The heart of the blending system is the load cells They monitor the weight in each of the ingredient weigh hoppers and the lower mass flow weigh hopper As the load cells are reading the actual material weight loss that is removed from the weigh hoppers by the feeders or the extruder the proper calibration of these load cells is essential for the correct operation of the blender This calibration must be performed upon initial installation and startup of the blender They should also be rechecked periodically with a calibration weight to ensure that they have not been damaged in the normal routine of cleaning color changes etc The calibration of each load cell is done by using two points on the output of the load cell scale The first of these points is known as the Tare Weight This is the weight of the empty hopper
19. d to install the continuous loss in weight blending system 1 Visually inspect the extruder or blender mounting location for obstructions 2 Remove the material supply hopper on the extruder flange 3 Carefully lift blender into place above the mounting flange on the extruder and fasten the blender to the flange using the extruder flange bolts Note Always lift the blender from the eyebolts on the top plate 4 Mount the weigh hoppers that were shipped in boxes on the crate to their respective load cells Don t forget the plastic dust cover on the bottom of the weigh hopper Align the discharge tube on the weigh hopper to be centered in the lower frame opening over the feeder assembly Use caution in tightening the bolts Adjust the gap to 0 040 5 Hook the manual mode level sensor bracket over the lower mass flow weigh hopper on the bottom of the blender Ensure that the cord is not binding on anything that would affect the accuracy of the weigh hopper 6 Check the wiring from the load cells to the control panel 7 Ensure that the motor power cords are connected to each of the metering unit motors Note Ensure that the augers on the blender metering units are not bent or damaged in shipping before starting the unit 8 Connect the control power to the motor control panel 9 Connect the compressed air piping to the inlet fitting on the top of the blender top frame Ensure that the air supply is regulated to a maximum of 60
20. der with your hands while it is running e Before you start the blender check the following o Remove all tools from the unit o Be sure no objects tools nuts bolts clamps bars are laying in the metering or mixing area e If your blender has been inoperative or unattended check all settings 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 o unsafe operation or condition o unusual blender action o leakage o 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 Continuous Loss in Weight Blenders Chapter 1 Safety 10 e Clean the blender and surrounding area DAILY and inspect the machine for loose missing or broken parts e Shut off power to the blender when it
21. ed 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 do the following e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device 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 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 continuous loss in weight blender 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 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 m
22. emote mass flow weigh hopper is located more than 25 feet from the blender control panel a load cell amplifier module may be required Note The manufacturer assumes NO responsibility for any damages resulting from improper installation or improper handling during the installation process Continuous Loss in Weight Blenders Chapter 3 Installation 25 Figure 8 Typical Layout for a floor mounted blender Remote Mass Flow Hopper Blower Venturi 470 LCD 3 3 Electrical Installation The continuous loss in weight blending system is designed to operate on 115 volt single phase 50 or 60 hertz AC power The power requirements will vary with the blender s size and throughput rating For exact current requirements check the blender serial number tag located on the blender motor control panel As an added option the manufacturer may provide a voltage transformer for special supply voltage If supplied they are rated for the load required by the blending system no other equipment should be connected to the transformer The additional equipment may induce noise into the power circuit to the blender as well as possibly overload the transformer The power transformer wiring and mounting is the responsibility of the customer If company or local codes require fusing or disconnects these items must be supplied wired and mounted by the customer Each blending system MUST be connected to a separate source of power Do not connect extra e
23. encing with operation of the Continuous Loss in Weight Blender These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the unit safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your Continuous Loss in Weight Blender provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death o
24. er 3 Installation 23 Note Never weld on the blender s frame machine or mezzanine without first removing the control panel and verifying that the blender s power is disconnected Mezzanine Mount In a mezzanine mount application review the following items before installation begins First verify the blender mounting locations match the mezzanine supports Verify that the mezzanine is capable of supporting the blender with a full load of material and loading equipment installed If the unit is unstable in the vertical or horizontal plane additional bracing of the mezzanine floor or blender side bracing will be required Remember that this is a precision weighing system It is only as accurate as the base it is mounted on If a blender is moving due to vibration the weigh hoppers will tend to remain stationary due to the laws of physics dealing with inertia This causes the load cells to output erroneous weight signals Note While in operation the blender applies both horizontal and vertical pressures to the mezzanine mount location Second verify ALL clearances to other equipment and structures Insure motors hoppers and control panels have proper clearance for operation cleaning and maintenance Note Auger assemblies require a minimum of 24 inches for proper cleaning and maintenance Ensure that the blender if feeding the extruder from an offset not exactly over the center of the extruder throat is mounted with the grav
25. er 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 Warranty Returns Prior to the return of any material authorization must be given by the manufacturer 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 the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms Continuous Loss in Weight Blenders ii Table of Contents CHAPTER T SAFETY cies arassa eean Saara esa gege gege 6 14 HOW to use this manual reete e eene pop Redi Pa EES daten 6 Safety symbols used in this manual 6 1 2 Warnings and PreECAULOMS x dita ex yee nd ve das wd val veces Au ru rp cadets cha ERN ER EAE RS 8 pc SI en cell REUS LT E 9 General responsibility MC Cnm 9 Operator E E 10 Maintenance responsibility EE 11 Reporting a safety defect eoe taie rere ot Ee eO RS voci tur eie reds persos 11 CHAPTER 2 FUNCTIONAL DESCRIPTION 12 2 1 Models covered in this manual reete ERA eek 12 2 2 General description
26. er supply A0563932 3 12 VDC power supply 739 00027 00 4 Alarm light Yellow strobe 24 VDC A0565889 5 Glass fuse 3 0 amp 115 volt A0542207 6 Ethernet module optional 40563939 7 Ethernet module cable 700 00278 00 8 120 volt light bulb power switch 715 01034 02 Figure 65 Typical Allen Bradley Display Main Parts List Description All MODELS 1 Allen Bradley PanelView Display ONLY A0563571 2 Allen Bradley PanelView flash memory card CONSULT FACTORY 3 PanelView 600 display Connection cable A0565856 Continuous Loss in Weight Blenders Chapter 6 54 Appendix Annex B Information The following design information is provided for your reference 1 No modifications are allowed to this equipment that could alter the CE compliance 2 Ambient temperature 40 degrees Celsius 104 degrees Fahrenheit Maximum 3 Humidity range 50 relative humidity 4 Altitude Sea level 5 Environment Clean dust free and non explosive 6 Radiation None 7 Vibration Minimal i e machine mounting 8 Special installation requirements Clean dry compressed air 1 cfm 60 psi 1 7 m3 hr 4 14 bar 9 Allowable voltage fluctuation 10 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 11 Nominal supply voltage 120 1 60 or 220 1 50 or 60 Verify on serial number tag 12 Earth ground type TN system has one point directly earthed thr
27. et oe Oe Preventative maintenance schedule 2 21 cna nctiia tea eter dette rt ket na GR pe na enn 52 APPENDIX BEB RRR RR RR RRR RRR RR RR RRR RRR RRR RRR RR RR RR RRP RR RR RRR RRR RR RR RR RRR RRR eee eee 54 6 1 Warranty and spare parts EE 54 Annex EE tel Eden DEE 55 6 2 Addendum Service supervisor Imformaiion 55 Frogrammablo Sellius s reddere ptr a ep Ee e pru eid 56 6 3 Technical assistance EE 63 Continuous Loss in Weight Blenders Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your Continuous Loss in weight Blender The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the blender We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before comm
28. go calibration after the initial calibration is complete if you note down the calibration values listed in the CAL VALUES box If you are changing back to a calibrated resin simply touch the box under Cal Values and enter the appropriate number FEEDER CALIBRATION Setting Hopper Size As the blenders are provided in several sizes and output ranges the system will need to know what size all of the weigh hoppers are on the blender The following is a reference guide for setting the hopper sizes The hopper size can change based upon the material s bulk density After a weight has been assigned to the hopper it should be monitored the first time it is filled to check the level The hopper size can be adjusted depending upon whether the level in the hopper is too high or too low Keep the hopper level full at least 2 to 3 inches below the upper surge hopper refill valve Continuous Loss in Weight Blenders Chapter 3 Installation 36 Figure 12 Hopper Sizes 12 14 14 18 20 40 24 60 Above lists standard sizes and can vary depending on the blender requirements and rates to be blended Larger hopper sizes are available on custom order Setting hopper size Touch the ACS Group logo and enter password 5413 ACS IS NAT ERE NIB Blender Stopped MF HER HH I 4truder Push to RPM Touch the OK button Continuous Loss in Weight Blenders Chapter 3 Installation 37 Touch Hop
29. hertz Extruder RPM Options RUDER RPM OPTIONS No Extruder Speed Measurement This gives you the option of having no extruder speed input writing the extruder speed to the blender through the Ethernet or using a proximity sensor on the end of the extruder screw Continuous Loss in Weight Blenders Chapter 6 Appendix 60 Allowed Extruder RPM Change for Steady Flag This is how much the extruder RPM can vary and still be considered steady With no extruder measurement the control always assumes a steady RPM Update Time for Prox Method in seconds This is how often the extruder speed updates from the prox Extrusion Control Options EXTRUSION CONTROL OPTIONS Not Avali lable Feeder Setup FEEDER SETUP This screen allows you to enter the maximum auger speed in Hertz Continuous Loss in Weight Blenders Chapter 6 Appendix 61 Advanced Alarm Options Time This alarm is for no material flow through a auger this could be caused by a blockage stopped motor etc No Flow Timer This is the amount of time used to measure the bit flow weight loss through a hopper to determine if an alarm is warranted No Flow Bits This is the amount of weight loss in a set amount of time No Flow Timer to sound an alarm Please contact the ACS Service Department with any other questions Continuous Loss in Weight Blenders Chapter 6 Appendix 62 6 3 Technical Assistance Parts Department Call toll free 7 am
30. in Weight Blenders Chapter 4 Operation 49 Recipe Page gt Start gt Next returns to Recipe VVVVVVVVVVVV Figure 15 Blender Menu Structure Standard Unit Continuous Loss in weight Blender Control System Menu Structure Inventory page Clear Inventory Extruder RPM is displayed Extruder throughput is displayed Blender throughput is displayed Blender percentages are displayed Hopper weights are displayed Steady flags are displayed Access Recipes Access Recipe Book Access Clean out Access Inventory Page Access Setup Page Next to access Inventory page page Clean out gt Run feeders manually Recipe Book Page Save the running recipe to the book 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 Setup Page gt Touch the ACS icon and enter in the user password Continuous Loss in Weight Blenders Chapter 4 Operation Hopper Setup gt Hopper size Calibration gt Scale Calibration gt Feeder Calibration Panel View Config Panelview GH version PLC GH version Password New Password Verify Password Units English or Metric FIFO Mass Flow FIFO Data gt Feeder FIFO Data Alarm Log View print and clear the alarm log Alarm Setup No Material Flow Re fill to Long No Material Load cell Failure
31. ine is added to the known total discharge rate from the blender weigh hoppers The sum of these two rates calculates the actual flow rate out of the bottom of the blender This is the processing rate of the processing machine that the blender is mounted on Continuous Loss in Weight Blenders Chapter 4 Operation 47 The blender will blend at a maximum rate when the lower mass flow weigh hopper has a very low weight of material As the weight of material increases in the mass flow weigh hopper the controller will adjust the blender feeders output to match the calculated processing machine rate The blender will adjust in so that it is running a very closely matched rate to the extruder and readjust the ingredient hopper outputs accordingly The processing rate and the blending rate displayed on the blender control will not match exactly for any extended period of time as the dynamics of the extrusion process produces a continuously changing rate for the extruder The blender will follow this dynamic changing rate very closely The learned processing rate is accurate enough for mono layer extrusion yield control or co extrusion layer thickness control If the extruder is slowed or stopped suddenly the blender will reach the high weight point in the lower mass flow hopper slow down and stop the metering devices so the weigh hopper will not overfill Manual Backup Control System Every continuous blender is equipped with a secondary manual backu
32. ity discharge tube at least at a 60 degree angle See figure 7 below This must be more than the angle of repose of the material or bridging in the discharge tube will occur and the extruder could starve The material connection should be made with rigid tubing if possible Figure 7 Offset Mezzanine Mount Position Mezzanine Floor Continuous Loss in Weiguc DICIIUCLS vVAlaptcr 2 LIptaltauot 24 Note Ensure that the feed tube angle is steep enough 60 degrees is recommended Note Some mezzanine mount applications will require the blending system s lower mass flow hopper be mounted on the extruder throat The metering section will be mounted on a small stand on the mezzanine directly above the extruder with a 4 tube stub for gravity metered flow Note This arrangement will be similar to the floor mounted configuration discussed in the following section less the blower assembly Using the proper lifting equipment lift the blender into place Take care to ensure the proper orientation of the blender and operator controls Note The manufacturer assumes NO responsibility for any damages resulting from improper installation or improper handling during the installation process Once properly positioned securely fasten the blending system to the floor Floor Mount In a floor mounting application ensure adequate clearance for all blender operations and maintenance The operator and maintenance personnel must have
33. n average and gives you a percent differential If the steady flag is a 1 the hopper is steady If it is a 0 it is not steady This means that the percent differential is greater than what the value is set to on the advanced hopper page The mass flow FIFO works the same way only you have to calculate the differentially manually gt FLOW FIFO DATA MF not in Steady Window MF Lbs MF Timer ob oN eg 6 L Si FEEDER Hopi Hopz Hop4 Hop5 Hop6 Continuous Loss in Weight Blenders Chapter 3 Installation 46 Chapter 4 Operation 4 1 Start up The objective of this chapter is to familiarize the reader with the blender s recipe menu run mode operation and displays Upon completion of this chapter the reader will be familiar with the recipe and run mode displays that are available on the continuous blending system The various sections within this chapter will be e General Operation e Run Mode Display e Recipe Menu All personnel operating the blending system should read this section of the manual BEFORE operating the blending system General Operation The general operation of the Continuous 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 Using the recipe menu enter a valid recipe After entering a recipe the operator will sta
34. n be blown out if it has collected Continuous Loss in Weight Blenders Chapter 2 Functional Description 16 Lower Mass Flow Weigh Hopper Assembly The lower mass flow weigh hopper otherwise known as the weighed common hopper is used to determine the actual processing rate of the processing machine so that the blender can be slaved in to run at the learned rate The hopper is constructed of spun aluminum and is of the mass flow type See the glossary in the Appendix It is supported by a load cell and will carry a weight of material depending on how much is flowing into the hopper from the metering augers and how much is flowing out of the hopper dictated by the processing rate of the processing machine The computer uses the mass flow hopper flow rate the differential rate along with the known total rate from the weight loss feeders to determine the actual processing rate of the processing machine The blender output rate is then adjusted to match the learned processing rate This method of operation provides very accurate slave in of the blender to the processing rate and eliminates the need for a mixing hopper The lower common weigh hopper is also equipped with a high level proximity level sensor to allow manually adjusted volumetric operation of the blender in the event of computer failure Figure 4 Weigh Hopper Assembly KNOWN DISCHARGE RATE FROM WEIGHT LOSS FEEDERS PROOUCING RECIPE RATIO cc ee PROXITY HIGH LEVEL SWITCH
35. n of the manual or program can be compromised Note Hidden programmable features and hidden menu pages should not be made available to floor operators These pages also include the Service Supervisor Information addendum located in this section Unauthorized changes to these factory settings by inexperienced operators may prevent the unit from operating properly and may void part or all of the warranty Caution After all selections are made Keep pressing the Done key until the unit returns to the Recipe menu Note Inexperienced operators or plant personnel should not access programmable features Unauthorized changes may prevent the blender from operating properly and may void part or all of the warranty Note Call the 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 Note Information included in this manual is subject to change without notice Passwords e User Password 5413 e Maintenance Password 3145348 Caution Maintenance password should only be supplied to qualified personnel The program can be compromised Programmable Settings The 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 Pressing the manufacturer s ico
36. n the feeder in question This would indicate a faulty load cell a material bridge in the re fill hopper or something obstructing load cell movement Re fill too long Weigh hopper is not being re filled in the allotted time This would be caused by the supply hoppers not be kept full Check the loading system No material This means the weigh hopper is empty Load cell Failure The controller is not properly reading the load cell Check the load cell Load cell over ma x The maximum weight limit on the load cell is exceeded Check weigh hopper size and material bulk density Extruder No Flow No weight loss is being detected in the Mass Flow hopper Make sure there is no material bridge above the extruder throat or interference with the Mass Flow load cell Blender Cannot keep up The extruder is running faster than the augers will allow the blender to run There are several options to set for the above listed alarms The following explains the options and how to set them up Continuous Loss in Weight Blenders Chapter 3 Installation 40 First you must get to the Alarm Setup Page To do this Touch the ACS Group logo ACS RECIPE 4 4HHHHHHH Group RE E o ULLA ULLA ULLA ULL 1 z 3 4 Blender Stopped Gei B lendin d Range MF HHHH tO HHHH 8 4truder HHHH to RPM H Ht er 8 Kas Hr Touch Alarm Setup Panel View Config User Password e FIFO DIAGNOSTICS Continu
37. n when in the Setup Directory Screen menu accesses this menu Continuous Loss in Weight Blenders Chapter 6 Appendix 56 Once you access the Engineering Menu you will see the following ENGINEERING ONLY Advanced Hopper Options Advanced PID Options Feeder Speed Limits This is where you make adjustments to fine tune the blender s performance You will need to assess the FIFO page previously mentioned in the manually to decide what changes need to be made The following pages will show you the setup parameters and how to adjust them Advanced Hopper Options Continuous Loss in Weight Blenders Chapter 6 Appendix 57 Feed Factor Filter This filter allows you to set the number of snapshots that the FIFO page looks at to find the average deviation Making this number bigger will cause the feeder to make changes slowly and decreasing the number will make changes faster You may want to make this number smaller on a feeder with a low feed rate Steady Feed Factor This is the parameter that sets the percent deviation allowed for the feeder to give a stable flag The lower the percentage the more accurate the feed With hard to feed materials or materials that vary in bulk density you may have to increase this number Also if a lot of vibration is occurring that cannot be resolved you may have to increase this Max WTP RPM This is the maximum weight through put per RPM allowed This is settable in case you have a
38. nter in the proper recipe and start the blender If it is desired to have a local display and control of the blender at the operator station an optional Panel View 600 can be installed Motor Drive Panel The auger motor drive panel is mounted on the blender frame adjacent to the PLC control panel in most applications The motor drive panel is permanently wired on the blender The standard panel contains Yaskawa GPD 205 variable frequency motor drives a power supply and manual volumetric backup system wiring components The motor drives on the blender are standard off the shelf drives and are readily available from Yaskawa distributors and the manufacturer Power cords to each drive motor are equipped with plugs to facilitate auger removal and motor replacement if necessary Optional Quick Color Change Kit The optional QCC quick color changeover kit allows the virgin material to be gravity fed so the processing machine can be operated while a color change is being done The virgin material auger metering assembly is equipped with a lower slide gate and discharge tube A flexible hose connects the discharge tube with a cast aluminum flange below the blender that is equipped with an angled inlet tube stub When the slide gate is opened virgin pellets will gravity feed to the bottom of the blender and bypass the blender augers and the lower mass flow weigh hopper allowing the extruder to be operated The blender augers can
39. number of your equipment before contacting the manufacturer for parts or service Blending systems are as varied as the applications they are designed for All continuous loss in weight blenders are sized to meet the specific requirements stated by the customer at the time of purchase and future changes my require a modification to the original system General Description All blenders are designed to blend plastic pellets and regrind and supply the blended material to the extruder The standard system is not designed to blend powder or any other no free flowing materials Consult the factory if your future process requirements require the addition of these materials Accessories The manufacturer offers a variety of options for these blending systems including mezzanine stands agitated regrind supply and weigh hoppers etc All accessories are designed and manufactured to ensure proper results for your application Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with these blenders 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 Note If you desire to use a blender for an application other than
40. ough a protective conductor 13 Power supply should include a neutral power connection 14 Over current protection is supplied in the blender control panel but additional protection should be supplied by the user 15 The plug on the power cord serves as the electrical disconnect device 16 Unit is equipped with three phase motors driven by single phase motor drive cards 17 Functional identification 18 Cable support may be required for power cord depending on final installation 19 No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance 20 Doors can be opened with a screwdriver but no keys are required 2 Two hand control is not required or provided 22 All hoppers should be moved around and set in place with a lift truck or equivalent 23 There are no frequent repetitive cycles that require manual control tepetitive functions are automatic while the blender is operating 24 An inspection report detailing the functional test is included with the OL blender 25 The machine is not equipped with cableless controls 26 Color coded harmonized power cord is sufficient for proper installation Continuous Loss in Weight Blenders Chapter 6 Appendix 55 6 2 Addendum Service Supervisor Information Note Personnel not extremely familiar with this blender controller should not use this sectio
41. ous Loss in Weight Info 41 All alarm parameters are selectable If you do not want to use an alarm for a feeder ensure the corresponding box has an N in it To be enabled the box must have a Y in it You can also decide to let the Blender continue to Run or Stop if an alarm is active To do this select Stop or Run in the boxes on the right Pop ups enabled means the alarms will be shown on the screen Select Pop ups disabled if you don t want to see the alarms on the screen Extruder flow alarm and Blender cannot keep up alarm can be enabled or disabled according to costumer requirements ALARM SETUP Disabled Communications All Allen Bradley Loss in weight blenders can be setup to communicate to a host via Ethernet an optional Ethernet module must be purchased to allow communications This can be used for loss in weight extrusion control or for data monitoring The window below shows how to set up the 1761ENI Ethernet module NETWORK INFORMA TO MODIFY THE IP ITBI CBE BR from ENI c Obtain via Boot IP ENI IP to ENI Continuous Loss in Weight Blenders Chapter 3 Installation 42 Setting Blender for English or Metric Touch the ACS Group logo Blending Range MF H HH HHHH aL E Extruder Blender 9 HH Blender r MF Extruder Touch Units Continuous Loss in Weight Blenders Chapter 3 Installation 43 Hopper Setu
42. p Hopper Setup Panel View Panel View Confia EA EH User Password Password Setup FIFO DIAGNOSTICS Touch the box that says English Units to toggle between English and Metric Note you must re calibrate the blender and reset the inventory values if you change this value NOTE If Blender Data is ed from either KGS or LBS you must recalibrate the blender and r et the inventory totals You must all hopper and at Lou setup How to use FIFO Diagnostics First you must get to the FIFO screen Touch the ACS Group logo ACS RECIPE zeg 44 Dog o ULLA ULLA ULLA ULLA 1 2 3 4 Blending Range MF San HH HHHH HCO HHH t Extruder Blender L Extruder Kas Hr Continuous Loss in Weight Blenders Chapter 3 Installation 44 Enter the Password and touch OK ord epted a Touch FIFO Diagnostics Hopper Setup Calibration Panel View Config User Password Units FIFO DIAGNOSTICS Select Mass Flow FIFO Data or Feeder FIFO Data FIFO DIAGNOSTICS MASS FLOW FIFO DATA Feeder FIFO DATA Continuous Loss in Weight Blenders Chapter 3 Installation 45 The Following screens will appear This data is provided for trouble shooting blender stability problems If you are not getting a steady system indication or if you are getting an unstable system alarm you can check here for the problem This is a first in first in first out table It takes a
43. p control system This allows the blender to be switched over to manual operation In this mode the feeder speeds are adjusted manually and the blender will run blending volumetrically The lower mass flow weigh hopper is equipped with a proximity sensor mounted on the upper level of the hopper This is for the manual operation to cycle the metering augers if the level of material in the weigh hopper reaches a high level This secondary control will allow the blender to be operated to provide production in the event of a control failure After correction the blender can be switched back into automatic operation When the blender is running in steady automatic mode simply check the motor voltages or frequency readouts and record them Then the drives can simply be dialed in for emergency volumetric operation Continuous Loss in Weight Blenders Chapter 4 Operation 48 4 2 Controller Description amp Operation Display Description The controller on the continuous loss in weight blender utilizes a LCD touch screen display Figure 14 Typical Controller Display ACS ae el a FER Blender Stopped Blending Range MF 33 3 HHHH H TO HEHE H Extruder Blender Push to RPM HHHH MF Extruder Kas Hr A typical menu entry is shown in the figure above Please refer to the blender menu structure shown in Figure 13 on the next page This figure shows a standard menu structure for the blending system Continuous Loss
44. per Setup Hopper Setup Hopper Setup Panel View Config View Confi Panel View Config User Password User Password Ber a FIFO DIAGNOSTICS Touch the box next to the hopper number that you want to change and enter weight value HOPPER SETUP HHH HHH HHH HHH HHH HHH HHH HHH Setting Passwords There are three levels of password security for the control system User factory set to 5413 Service ACS only cannot be changed factory set to 3145348 Continuous Loss in Weight Blenders Chapter 3 Installation 38 To change a password proceed as follows Touch the ACS Group logo Touch User P Continuous Loss in Weight ACS Group Blender Stopped Push to HHEHHH HH LT eee ieee aie eee eit ate ULLA 1 2 3 4 Blending Range MF San HH HEHH o HHHH t truder Blende RPM 44 SE eet Dr assword Network Info Hopper Setup Hopper Setup Calibration Panel View Panel View Config User Password User Password EA 39 Enter original password Touch box next to select operator until you see the level you want to set operator service Touch New Password and enter your new password Touch Verify Password and verify you new password USER PASSWORD SETUP Select Operator ererereree errs ee Alarm Setup There are several alarms in the blender control they are as follows No Flow No weight loss is being detected o
45. quipment on the same line with or without use of the transformer It is the customer s responsibility to ensure that the power requirements of the blending system are satisfied Continuous Loss in Weight Blenders Chapter 3 Installation 26 3 4 Pneumatic Installation The blending system utilizes air pneumatics to perform the re fill function on the ingredient weigh hoppers The manufacturer provides all pneumatic plumbing to a single 14 standard pipe thread fitting The blender requires a maximum of 60 PSI of compressed air It is the customer s responsibility to ensure that the air is CLEAN DRY amp LUBRICATED Any component failures due to airborne contaminants will not be subject to warranty consideration The working range of the air pressure is from 40 60 PSI PSI lower than 40 may result in shutoff valve failure PSI greater than 60 may result in damage to the plunger cones in the re fill hoppers A 5 micron filter is recommended Note It is the customer s responsibility to provide proper air pressure regulation filtration and lubrication devices Figure 9 Pneumatic Air System RELOAD CYLINDER FILTER REGULATOR LUBRICATOR UNIT 100P S 1 AIR SUPPLY __ AW AYVALVE BLENDER RELOAD VALVE DUMP CONE Continuous Loss in Weight Blenders Chapter 3 Installation 27 3 5 Overall Installation Summary This installation procedure should be used as a general guideline for the proper installation steps require
46. r serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Continuous Loss in Weight Blenders Chapter 1 Safety 6 Allen Bradley Controls Continuous Loss in Weight Blender Safety Tags Tag Description Tag Description Pinch Point Slide Gate Read Operation amp Installation Manual Shear Point Rotating Mixer or Agitator SS Earth Ground High Voltage Inside P E Protected Earth Ground Enclosure Shear Hazard Rotating Auger Lifting Point Continuous Loss in Weight Blenders Chapter 1 Safety 7 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following pertinent local and national codes This may include but is not limited to OSHA NEC NFPA CSA UL CE SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices EN M M m Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instruction
47. repaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have M Bill of lading M Packing list Kl Operating and Installation packet V Electrical schematic and panel layout drawings Kl Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the Parts and Service Department immediately Have the order number and item number available Hold the items until you receive an RMA number and shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Continuous Loss in Weight Blenders ii Credit Returns Prior to the return of any material authorization must be given by the manufacturer 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 the manufacturer 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 numb
48. rtup the blending system This will begin the general operation of the blending system Note Before starting the blending system each ingredient hopper in the recipe MUST contain material Once the operator initiates the run mode of operation the blending system controller will start the metering devices The metering units will start out at the maximum metering rate at speeds based on the feeder calibrations that were learned during the prior setup of the blender The blender will output the maximum rate that is achievable with the feeder sizes and the recipe percentage that is entered in the current recipe Each metering unit will meter its material out of its respective weigh hopper at the correct rate to achieve the programmed blend ratio and discharge it into the cascade material chute above the lower mass flow weigh hopper The metered ingredients cascade together into the weighed common hopper The PLC looks at the weight change in the weighed common hopper over time and learns The discharge rate from the common weigh hopper to the processing machine This Discharge rate from the common hopper to the processing machine is the learned rate that occurs internally within the weighed common hopper and is the difference between the rate of material entering into the top of the common hopper and the rate of material flowing out of the bottom of the common hopper The learned Discharge rate from the common hopper to the processing mach
49. s This design eliminates extra variables such as auger drive vibrations etc from the weighing system and increases the load cell resolution Each weigh hopper will be refilled periodically as material reaches the preprogrammed low weight setpoint for that hopper Clear hopper side walls or sight glasses are provided on each on the weigh hoppers to allow the operator to monitor the levels Continuous Loss in Weight Blenders Chapter 2 Functional Description 15 Ingredient Metering Transport Auger Assemblies Each metering auger assembly consists of a e Cast aluminum motor mount e Cast aluminum feeder body e Aluminum feeder tube e Gearbox e Inverter duty AC drive motor e Machined metering auger The metering auger assembly accurately meters the material from the ingredient weigh hopper at the calculated rate The mass flow weigh hopper design allows more range of the load cell to be used for actually weighing the material and eliminates dynamic drive movement and vibrations from affecting the load cell readings Figure 3 Metering Auger Components A C DRIVE MOTOR E m AUGER TUBE em A z 3 p PET METERING AUGER Ay Cascade Material Chute The cascade material chute is a rectangular conduit in which all the metering augers discharge The materials are cascaded together and directed vertically down into the lower mass flow weigh hopper A clean out door is provided on the chute above the augers so that any dust ca
50. s become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Keep fingers away from slide gates augers clean outs and calibration hatches Automatic operation may start unexpectedly A PINCH HAZARD CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power and compressed air before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA Make sure the equipment and components are properly GROUNDED before you switch on power Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Continuous Loss in Weight Blenders Chapter 1 Safety 8 1 3 Re
51. s mechanically capable of supporting the weight of the continuous loss in weight blender with a full load of material and the loading system installed Note While in operation the continuous loss in weight blender applies horizontal and vertical pressures to the mounting flange The vacuum system will cause some shaking due to the dynamics of the conveying operation Note If there is a question as to the mechanical stability of a mounting flange the appropriate reinforcements and lateral supports must be provided to ensure a safe installation Check to ensure that the unit is braced to prevent swaying if necessary Contact the manufacturer 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 Note Allow at least 24 clearance around auger assembly to provide adequate room for cleaning servicing etc Using proper lifting equipment lift the blender into place above the machine throat and secure the flange bolts Check to ensure that the unit is properly oriented and that there is adequate access around the blender for operating and servicing of the panels and cleaning of the feeder units A work platform with OSHA approved handrails is recommended Take care to insure proper orientation with adequate access to operator controls mix chamber and metering units Continuous Loss in Weight Blenders Chapt
52. s or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for 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 Continuous Loss in Weight Blenders Chapter 1 Safety 9 Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment 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 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 material out of the blen
53. s the intent of this section to familiarize the reader with the proper site requirements and installation procedures of the continuous loss in weight blending system The information in this section is NOT meant to replace or supersede an established local or company implemented procedures It is meant to enhance them Note The manufacturer assumes NO responsibility for any damages resulting from improper installation or improper handling during the installation process Continuous Loss in Weight Blenders Chapter 3 Installation 22 Site Requirements This section describes site requirements in detail These requirements are broken down into mechanical mounting electrical connections and pneumatic connections Since the continuous loss in weight blender is available in several different mounting arrangements it is necessary for the reader to become familiar with the different arrangements Mounting Configuration The continuous loss in weight blender is available in 3 three basic mounting arrangements They are e Machine Mount e Mezzanine Mount e Floor Mount Machine Mount In a machine mounting application of the continuous loss in weight 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 continuous loss in weight blender flange or the optionally provided adapter flange dimensions Verify that the machine material inlet flange i
54. scales on each of the feeder units follow the instructions below Continuous Loss in Weight Blenders Chapter 3 Installation 32 Touch the ACS Group logo in the upper left hand corner You will be prompted to enter a password it is 5413 ACS RECIPE di sii E 1 01 EE Ul LLLA ULLA ULLA ULL 1 2 3 4 Blender Stopped MF HH HH EXT struder Push to RPM Touch the Calibration button Hopper Setup Hopper Setup Panel View Config User Password FIFO DIAGNOSTICS Continuous Loss in Weight Blenders Chapter 3 Installation 33 Touch Scale button Find your calibration weight that shipped with the blender and locate the Weight information stamped on the weight proceed as follows 1 2 3 4 5 You can also check the calibration by looking at the in LBS box and hanging your calibration Enter weight value stamped on the weight in Cal Wt Box Make sure weigh hopper is empty then touch Set Zero Hang Calibration weight on weigh hopper and touch Set Cal Wt Repeat for all Hoppers including Mass Flow Touch done when complete weight on the weigh hopper to be checked SCALE CAL Feeder Calibration This section will explain how to calibrate the feeders on your OL blender This must be done on initial startup and whenever material is change and bulk density varies greatly You must make sure that the feeder to be calibrated has resin available Also note that resin will
55. speed you may also write extruder speed through Ethernet in lieu of using the proximity switch 115 1 50 or 60 supply voltage Continuous Loss in Weight Blenders Chapter 2 Functional Description 13 Blender System Component Description This section describes the various components of the continuous blending system The continuous blending system is made up of the following components See Figure 2 below e Ingredient supply re fill hoppers e Ingredient weigh hoppers e Ingredient metering auger assemblies e Cascade material chute e Lower mass flow weigh hopper e Control panel e Motor drive panel e OPTIONAL Quick color change kit Figure 2 Continuous Blender Assembly Supply Reload Hoppers Ingredient Weigh Hoppers Incradiont Auger Assemblies See Page 4 Cascade Material Chute Lower Mass Flow Weigh Hopper Motor Drive Panel not shown Ingredient Supply Re fill Hoppers The ingredient supply re fill hoppers are located on top of the blender frame Their purpose is to provide a supply of material to the individual ingredient weigh hoppers on demand The hoppers are equipped with an air operated discharge valve that is opened by the PLC when a respective weigh hopper needs a re fill of material These hoppers are sized to handle the percentage requirements of the ingredients Optional level sensors which might exist in these Continuous Loss in Weight Blenders Chapter 2 Functional Description 14 hoppers
56. sponsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that safety is always a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale Costly damage to equipment e Downtime 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 continually reviewed maintained and improved Keep minute
57. 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 Continuous Loss in Weight Blenders Chapter 2 Functional Description 12 2 3 Typical Features amp Components Mechanical Features Blender automatically adjusts individual feeders to match learned extruder rate at the ratio required Upper material supply hoppers with conical re fill valves and dust boots Individual ingredient weigh hoppers with clear side walls Cast aluminum feeder housings with drains Lower mass flow weigh hopper assembly with clear side wall Cascading mixing section Precision 10 span accurate cantilever load cell weighing system Yasakawa GPD 205 variable frequency drive VFD system with 1 4 hp inverter duty brushless AC motors Motor drive panel NEMA enclosure Machine mount spool flange with drain Hopper lids arranged for manufacturer and non manufacturer receivers and loaders Controller Features Color Allen Bradley Panel View 600 color touch screen o Easy menu driven format o Serial printer port o Recipe storage book o Inventory and material usage information o OPTIONAL Ethernet communications module Manual operation capabilities for emergency use in case of processor failure Electrical Features Inductive proximity switch for extruder
58. ust 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 motor and the safety switch fails the motor should not be run Continuous Loss in Weight Blenders Chapter 2 Functional Description 20 Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on the continuous loss in weight blenders are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the 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 A padlock should be placed in the lockout handle by personnel servicing the equipment WARNING At no time should anyone other than the person who installed the lockout or unplugged a twist plug remove the lockout or reconnect the twist plug Pluggable Line Cord This line power cord allows the operator or maintenance personnel to unplug the blending system from its power source and tag it out This plug may be tagged with any number of approved electrical lockout tags These t
59. ve completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the blender until all persons are clear of the area DO NOT start and run the unit until you are sure all parts are functioning correctly BEFORE you turn the blender over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Continuous Loss in Weight Blenders Chapter 1 Safety 11 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for continuous loss in weight blenders of various blending rates and specifications See Figure 1 below for a list of available models and specifications Figure 1 Models Covered by this Manual V Denotes Availability 2 2 Blending Capability eme f 750 SE 3000 1360 5000 2270 N Actual rates will vary Consult the Steeg for guaranteed blending rates Model numbers are listed on the serial tag Make sure you know the model and serial

Sterling Allen-Bradley 060 User's Manual

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