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ACS Blender CSG User's Manual

1. HD Heavy Duty RD Regular Duty Some assembly may be required Regrind Auger Metering R A M Hopper Used for feeding difficult regrind materials Figure 15 Typical R A M Hopper Blender Configuration BLN1 600A Chapter 2 Functional Description 31 of 116 Additive Feeder Hopper Used for feeding pelletized additive typically used on blenders with more than six components Figure 16 Typical Additive Feeder Configuration Take off Compartments Allows material to be metered into a vacuum conveying system 2 5 Safety Features This section includes information on safety devices and procedures that are inherent to the Gravimetric Batch Blender 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 BLN1 600A Chapter 2 Functional Description 32 of 116 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 Understand the proper use of the safety devices provided 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
2. BLNI 600A Chapter 7 Appendix 108 of 116 7 5 COMMUNICATIONS AND WEB SERVER The Blender has a Red Lion touch screen that has a built in Ethernet port This port s IP address can be configured via SETUP DISPLAY CONFIG Once configured you can connect the display to your plant s network The display software has a built in webserver that will allow you to view and control your blender as if you were in front of it using any web enabled device or computer If your facility has WiFi then the blender can be viewed controlled wirelessly via your smartphone ACS BD Blender Windows Internet Explorer o v IE 192 168 5 1 File Edit View Favorites Tools Help Sly Favorites 9 DIGISPONTABLE Mitel Audio and Web Confer HealthStream Learning Cent Insig ACS BD Blender ACS BD Blender Option Description View Logs Download files from the data logger Remote View Display a view of the HMI s display and keyboard Powered by Red Lion Open your web browser and in the address bar enter the IP address for the blender s display This will bring up a page where you can either view the blender s data logs or use the remote view feature AB COMMUNICATIONS INFORMATION The AB blender uses a Micrologix 1500 LRP processor that communicates with the outside world using DF1 protocol with Ethernet hardware Its Ethernet speed is 10 100 Mbits second The blender must be purchased from ACS with the Etherne
3. A programmable logic controller PLC controls the blender operation 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 See the following pages for controller pushbutton amp touchscreen tags along with typical operator screens If it is desired to have a local display and control of the blender closer to a remote operator station an optional remote mount operator panel is available STARTUP SCREEN ACS Batch Blender Display Software Version PLC Software Version PATENT 6811301 Copyright 2012 BLN1 600A Chapter 2 Functional Description 22 of 116 Changing the Language Touch here to bring up Language Selection Page Language Selection Fage Touch the Flag of your Country to change the language BLN1 600A Chapter 2 Functional Description 23 of 116 Recipe Page Touch screen interface is unlocked To lock touch the lock icon and enter in the password Touch screen interface is locked This prevents someone from starting stopping the blender or changing the recipe To unlock touch the lock icon and enter in the password Blender is not running Touch to start blender Blender is running Touch to stop blender The blender will then stop after it has compl
4. 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 To prevent damage to the equipment do not exceed 60 psi 4 14 bar air Always disconnect the compressed air supply when working on any part of the blender Initial Set up This section will discuss the mechanical setup and control system setup of the Slide Gate blending system After reading this section you should be familiar with the mechanical setup and the electronic control setup of the blending system BLN1 600A Chapter 3 Installation 41 of 116 Mechanical Set up Stroke Limiters for Metering Gates Stroke limiters are supplied on components through 6 with all Slide Gate blenders to allow standard metering gates to meter small amounts of low percentage additive materials Generally the stroke limiter is not required on major ingredients usually number 1 and 3 and should be adjusted to the rear most position If they are used on components number 1 and 3 the throughput of the blender will be reduced To install the stroke limiter drop it into the d
5. ACAUTION The pneumatic system used on the Slide Gate blender lihe all pneumatic systems 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 BLN1 600A Chapter 2 Functional Description 20 of 116 Mix Chamber All of the 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 Figure 8 Typical Mixer Assembly BACK PLATE GEAR MOTOR HI LEVELSENSOR MOTOR MOUNT BRACKET COUPLING AGITATOR MIXER DRAWER MIXER WRAP O LO The mixer is designed to provide bi directional mixing action and can be easily taken apart for cleaning This design 1s standard on all Slide Gate blenders Blades may be sharp BLN1 600A Chapter 2 Functional Description 21 of 116 Operator Control Panel Display The operator control panel includes an 8 foot 2 4 m cable and can be remote mounted not recommended adjacent to the blender The panel can be unplugged and removed if necessary
6. Mechanical Options Screen MECHANICAL OPTIONS e Time ebre Mier Bump SES AMA GATE CYCLE TIME 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 or air cylinders This setting will vary depending on whether you are using a gate or an auger Essentially it is the amount of time required to open close or start stop the feeding device SETTLE TIME The amount of time to settle the weigh hopper after the feeder has metered before determining final weight Be sure that this is set to a value greater than WEIGHT FILTER LOADCELL SAMPLETIME both on Advanced Weight Options Page Never set less than 3 seconds NUMBER OF LOADCELLS based on your blender s configuration MIXER BUMP TIME if the mixer is at high level it will bump the mixer on for this many seconds every 30 seconds This helps prevent an issue where the high level prox is set incorrectly and picking up the mixer blade instead of actually being at high level MIX SINGLE BATCHES Mixes single batches and then dumps them into the process If set to MIX TO FULL then it will mix multiple batches together before dumping them into the process This is useful when filling gaylords in order to achieve batch to batch averaging BLN1 600A Chapter 7 Appendix 103 of 116 Feeder and Type Setup FEEDER AND TYPE SETUP TOP VIEW OF BLENDER PANEL SIDE BLENDER FRONT i d
7. Date y B B B B B B B B B B B B B Tcp TT TT ILI any loose parts tighten them Verify quality of compressed air supply Verify mixer door is properly latched Inspect metering gates for proper operation Check to make sure that all hose connections are air i l L bl b tb pe Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Inspect air regulator and air safety circuits if equipped Recalibrate blender only If necessary Photocopy this page for your maintenance records BLN1 600A Chapter 5 Maintenance 76 of 116 5 2 Preventative Maintenance Our blenders need periodic maintenance to provide long dependable service Check these elements regularly Check functionality of safety circuit daily e Maintain proper air pressure and drain water from trap assembly on regulator as required e Periodically lubricate slide gate rails A WARNING Always remove plug and disconnect power before servicing blender Always read operating manual before operating or servicing blender For gear boxes on BD SGBD CSG 4000 6000 and RAM units with right angle gear boxes Change oil after initial break in period of 250 hours of operation and at 2500 hours of operation or 6 month intervals after break in period Recommended oil is Mobil SHC 634 Synthetic oil 5 gal P N OIL0041 Oil Capacity Part Description Part Number BE Ounces 4000 6000 Right 08505 IT BLN1 6
8. Parts Mode Often used in Compounding Applications 64 RECIPE SEUD e 64 Mixer ANG DUrmb Setilbuseitetiacva ctam tav tett teta xime ve nera AAG 68 AVI NIU cec 70 FIMO TC QU CS rea a a a E 2 COOK CAA OOS ES 3 4 9 SOU dOM et email ciat teca 5 CHAPTER 5 MAINTENANCE eren 76 5 1 Preventative Maintenance Schedule cccccc cece eecseeceeeceececeaseceeseeeceeeseeeeeenseeseeaeers 76 5 2 Preventative Maintenance ssssssessesssssssssesee see sne nenne nennen nass i sse a asse rne nn Tf 5 9 GCorrecuve Ma EN AICO iri issn aletes etc alt UR ein al oam eres 8 CHAPTER 6 TROUBLESHOOTING eene 80 651 JNTOQUEUO Me EE STEUERN 80 GHAPTER 7 APPENDIX scorri Ee 85 Annex B IBIOFmiatiQEu etenim eme eet pred leu ecoute ow diu ment nda connate 85 lA Drawings and DIagratms aieo Rae ea dee ga e Ode don e due hi RERO ead dat E E Hua 86 UTR IAS S CID CLE 86 DM Diamond SQ OUUSEE etat etc aga 86 7 4 7 5 7 6 MIXGF OUDSASSONIDIVI S ais ce peines teua ddan canon Gade dc ue tat 87 Hopber Sub assembly esie ents bete Du ies ate lt eu pone tese oa 89 Hopper R A M Regrind Auger Metering Sub Assembly Optional 90 Weigh Hopper oubsassembly 2 mini er E ede ictu UE Chr a e pase ap nette 92 Slide Gate Sub assembly tentis ioo end net aes eee 93
9. Provide a correctly sized and protected power supply to the unit If an electrical supply disconnect is not installed as a factory option the customer is responsible to properly size and install a suitable disconnect Refer to National Electric Code NEC 430 24 26 for proper feed conductor and supply disconnect sizing Voltages must be within plus or minus ten percent 10 of the nameplate rating Maintain a safe ground and disconnect the power supply before servicing the unit NFPA Article 250 A qualified electrician should make electrical connections and disconnect the electricity when service calls are needed Improper electrical connections can damage the unit and cause serious operator injury or death MAKE SURE THAT ALL ELECTRICAL CONNECTIONS ARE MADE BY A QUALIFIED ELECTRICIAN AND THAT ALL CONNECTIONS ARE TIGHT e Each 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 BLN1 600A Chapter 3 Installation 40 of 116 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 functio
10. 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 have 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 BLN1 600A Chapter 1 Safety 13 of 116 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for the
11. hop4 low level b29 2 3 this alarm is only available if the hoppers have low level prox switches 18 R hop5 low level b29 2 4 this alarm is only available if the hoppers have low level prox switches 19 R hop6 low level b29 2 5 this alarm is only available if the hoppers have low level prox switches 20 R hop7 low level b29 2 6 this alarm is only available if the hoppers have low level prox switches 21 R hop8 low level b29 2 7 this alarm is only available if the hoppers have low level prox switches 22 R plc battery low s 5 11 23 R ple memory module loaded s 5 8 this alarm only happens while upgrading the blender s software BLN1 600A Chapter 7 Appendix 110 of 116 INVENTORY INFO 1 RW clear inventory b3 0 3 toggle this to clear all inventory you must also reset this bit after completion 2 RW batch counter L30 31 f39 37 number of batches made 3 R hopl inventory L30 0 this is the whole portion of the inventory f39 3 entire number 4 R hop2 inventory L30 1 this is the whole portion of the inventory f39 4 entire number 5 R hop3 inventory L30 2 this is the whole portion of the inventory f39 5 entire number 6 R hop4 inventory L30 3 this is the whole portion of the inventory f39 6 entire number 7 R hopS inventory L30 4 this is the whole portion of the inventory f39 7 entire number 8 R hop6 inventory L30 5 this is the whole portion of the inventory f39 8 entire number 9 R h
12. recipe ingredient will not be shown on the recipe setup menu e ADD Additive designations will weigh the ingredient as a percentage of natural material only e RGD Regrind designations will weigh the ingredient as a percentage of the total batch It is assumed the regrind has been generated from pre blended production and already contains the same color and or additives e Virgin material must be loaded into hopper 1 and regrind into hopper 3 e 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 BLNI 600A Chapter 4 Operation 62 of 116 Figure 36 Example Calculations of a 5 component blend in EZ Recipe mode Virgin NAT 22 Additivel 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 lbs 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
13. set IP AC S SETUP Group Display Software Ver on PLC Software Version PATENTX 681130 Ea Copyright 2012 S 5 UEM tS 1921655 11 DispBrightness 100 BLN1 600A Chapter 3 Installation 51 of 116 Units Configure the blender for LBS or KGS AC S SETUP Group HOTE If Blender Data is changed from either KGS or LBS you must recalibrate the blender and reset the inventory totals You mustalso check inventory shutdown levels and batchsize Mixer and Dump Setup ACS Group MIXER SND DUMP SETUP Mix Time Remix Time Dump Time Dump Delay Dump Cycles uia uud d4secs The settings listed below are set at the factory and typically do not require any change BLNI 600A l p From Setup touch Mixer and Dump Setup Enter a Mixing Time This is the amount of time to run the mixer after a batch is dumped into the mixing chamber Use Remix Time to set Re mix off time If set to a non zero value the mix cycle will be ran every re mix seconds while the blender is at high level Use Dump Time to set the amount of time the weigh hopper will open while dumping This should not be set too long or short Use 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 Use Dump Cycles to enter the number of times that material will be dumped f
14. was manually cleared may or may not reflect the current recipe inventory Some customers like to run an accumulated inventory on ingredients coming from silos etc even though several different recipes have been run on the blender Others like to clear the inventory every time the recipe is changed The blender gives the operator the choice of either method The Report Setup Printer Menu contains four 4 options e Batch Interval e Print Inventory Clear Inventory Display Time amp Date Batch Interval or Timed Interval Printout BLN1 600A Chapter 4 Operation 72 of 116 The Batch Interval item under the Recipe menu works in conjunction with the Auto Print Interval to set the number of batches between printouts or on a timed interval between printouts Timed Printout When entering the Report Setup menu the operator will have to decide whether the printout should be timed and by the number of batches between each printout The operator will have to toggle between the Recipe Format and the Report Setup screens to configure the settings properly If you want to print out on a time format press the button next to the Auto Print Clear Interval key The screen will then prompt the operator to set the time interval in hours 1 to 24 If you want to change the hours between printouts press the Auto Print Clear Interval key again to change the value to the desired time The operator will then need to program
15. 08292 O 6 MOUNTINGBRACKET AIRCYLINDER P 3308 0 0 ee EE ES eer 9 MOUNTING NUT AIR CYLINDER AS53239 33090 BLN1 600A Chapter 7 Appendix 94 of 116 Knife Gate Sub assembly RD Optional Figure 63 Typical Slide Gate floor stand Assembly Parts List All Models 872 00297 00 872 00298 00 832 00049 00 872 00236 00 245 00016 00 A0770296 35086K 10 4 ES A0533862 8 EF 10 BLN1 600A Chapter 7 Appendix 95 of 116 Control Panel Layout g a BLENDING SYSTEM POWER SAFETY SLIDE GATE OFF ON ACTIVE OPEN o l auto HH cLOSE O G CAUTION DISCONNECT ALL POWER TO SYSTEM BEFORE SERVICING Figure 64 Typical Allen Bradley Controller Main Parts List Description 150 500 900 2500 4000 6000 4 Calex Module Load Cell Amplifier 7240011700 6 Alarm Horn 95db 24vde 7360005900 1 8 Motor Overload MCP Iv unit __ _A0858252_1_A0S68255 LAS D cr EE Power Switch 115v unit Power Switch 230v unit 717 01040 02 Safety Active 24vdc Figure 65 Typical RED LION Display Main Parts List 4 Description 150 500 900 2500 4000 6000 Red Lion G306A 744 00325 00 Touchscreen Display 744 00325 00 Enclosure Mounting Feet A0567132 3 Display 8 ft Connection Cable A0565856 Display 50 ft Connection Cable A0565899 Parts list for current blender s
16. 1 Safety 11 of 116 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 blender with your hands while it is running Before you start the blender check the following e Remove all tools from the unit e Be sure no objects tools nuts bolts clamps bars are laying in the metering or 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 ACAUTION 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 Report the following occurrences IMMEDIATELY unsafe operation or condition unusual blender action leak
17. 116 Figure 58 Typical R A M Hopper Assembly Parts List DESCRIPTION 50 900 2500 j 4000 6000 1 07822 1 4 DRAIN HOUSING OO 08806A HYD 5 DRAIN SLIDE GATE MOTOR MOUNT BRACKET SEAL AUGER TEFLON MOTOR AUGER AUGER HOPPER 2 0 CU FT HOPPER 7 0 CU FT DOOR A LATCH SAFETY INTERLOCR SWITCH BRACKET SAFETY SWITCH SIGHTGLASS 4 5 MOTOR AGITATOR AGITATOR SEAL AGITATOR RUBBER RECEPTACLE 3 PIN FEMALE CORD 3 PIN MALE 6 FT LONG STEADY STATE RELAY 10 AMP GLASS FUSE 3 0 AMP 115V UNIT J 1 ET 6 Las 8 ES BLN1 600A Chapter 7 Appendix 90 of 116 Hopper Additive Feeder Sub Assembly Optional 0 1 AUGER ASSEMBLY 1 AUGER COUPLING MOTOR AUGER PIN MOTOR MOUNT NOT SHOWN RECEPTACLE 3 PIN FEMALE NOT SHOWN CORD 3 PIN MALE 6 FT LONG NOT SHOWN STEADY STATE RELAY 10 AMP NOT SHOWN GLASS FUSE 3 0 AMP 115V UNIT NOT SHOWN GLASS FUSE 1 5 AMP 230V UNIT NOT SHOWN DESCRIPTION 500 900 2500 4000 6000 THROAT MOTOR MOUNT BRACKET MOTOR AUGER THROAT ADAPTER 2 RISER HOPPER 1 0 CU FT N A HOPPER 2 0 CU FT A0541208 SIGHTGLASS AF CLEANOUT COVER PLATE SAMPLE PORT N A Figure 59 Typical Additive Feeder Hopper Assembly Parts List COVER PLATE HOPPER A0541215 TRANSFER TUBE 1 AUGER A0541294 63119 hi ea 5 6 7 8 ER 10 EXE BLN1 600A Chapter 7 Appendix 9
18. 6 Troubleshooting 82 of 116 Check the Mixer and Dump Setup to see if the mixer is configured for Continuous Mixing 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 Mixer won t shut off and runs Check the power source to the blender continuously 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 Go to the Manual Control Page and check to see if Hop Low equals 1 If it does then adjust the low level prox until the value reads 0 Ensure that the material hopper is properly vented If the vacuum receiver is leaky then this will cause the problem To test this fill up the hopper and turn the loader off to prevent leaking Out of Material Alarm or Low Level is displayed but there is material in the hopper If this isn t the problem then increase th
19. Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Main 25 or Additive 10 Group Model Number Hop4 Alarm No Alarm on Out of Material BLNI 600A 2 1 13 F Blender Factory Default Setup Parameters Revision Level Modified By Keith Packard BD 900 BD 2500 BD 4000 BD 6000 OS 014 OS 070 OS 100 BD 150 BD 500 CSG 150 CSG 500 CSG 900 CSG 2500 CSG 4000 _CSG 6000 ALL WEIGHT VALUES RECORDED IN POUNDS DIVIDE BY 2 20462 FOR KILOGRAMS ALARM Hop5 Alarm No Alarm on Out of Material ALARM Hop6 Alarm No Alarm on Out of Material ALARM Hop7 Alarm No Alarm on Out of Material ALARM Hop8 Alarm No Alarm on Out of Material ALARM Missing Ingredient Comp Off Accept Recipe Alarm Off Out of Material Alarm Silence Dela 60 NETWORK SETUP Ethernet Module Configured Here YES Modbus Enabled Disabled DISABLED IP Address 192 168 0 10 Subnet Mask 255 255 255 0 Chapter 7 Appendix A0770601 OA 012 OA 030 OA 060 SGB 450 SGB 900 SGB 3500 SGB 5000 SGDB 150 SGBD 500 SGBD 900 SGBD 2500 SGBD 4000 SGBD 6000 SGA 012 SGA 030 SGA 060 107 of 116 Blender Factory Default Setup Parameters 2 1 13 F Keith Packard OS 007 OS 014 OS 070 OS 100 BD 150 BD 500 BD 900 BD 2500 BD 4000 BD 6000 OA 012 OA 030 OA 060 Model Number SGB 450 SGB 900 SGB 3500 SGB 5000 SGDB 150 SGBD 500 SGBD 900 SGB
20. BD CSG and SGBD Series slide gate blenders of various blending rates and specifications See below for a list of available models e 150 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls e 500 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls e 900 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls e 2500 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls e 4000 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls e 6000 Ibs hr Slide Gate Batch Blender with Allen Bradley Controls Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Blending systems are as varied as the applications they service All slide gate blenders are sized to meet the specific requirements stated by the Customer at the time of purchase General Description All 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 Accessories The manufacturer offers a variety of standard options for blenders including floor stands RAM feeders loading equipment 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
21. Batch 3 for c Feed Cal Allowed Deviation for TEM 1 WeightPerSecond Butter Stable Flag i Hop1 o5 10 MURS EE i Above batch size for Max Weight Alarm 45 Hop2 10 54 NOTSTABLE YET Batch dump settle time Bsecs Hop3 EE sox NOTSTABLE ver Hop4 ff RG NOT STABLE YET Loadcell Sample Time S00 msecs Simulation ON Print Weight Data every Batch 3 208 LBS WEIGHT FILTER The number of loadcell samples to be averaged when determining weight MAX TARE OFFSET Maximum allowed weight remaining in weigh hopper after dumping before Calibration Error Alarm WEIGHT SEC FILTER This is only used if the Weight Per Second Buffer is off This is a weighted median filter that will dampen changes to the Weight Sec value of each feeder Increasing this will dampen the change WEIGHT PER SECOND BUFFER When enabled the blender analyzes 3 consecutive batches Weight Sec measured values If these 3 are within the Allowed Deviation for Stable Flag Feeder Calibration Setup Page then the measurements are considered stable If the blender has went through a certain number of batches without stabilizing Unstable Alarm Limit on Feeder Calibration Setup Page then an Unstable Alarm will occur for that feeder The 3 measurements are averaged to come up with the Wt Sec value Feeder Calibration Page This is then used when calculating the metering time for that ingredient When this feature is
22. T Di CL ei This page allows you to configure how many hoppers your unit has as well as the position of each feeder visually You can make any hopper any number as long as you don t skip a number For instance if you have a 4 component blender then you will need to make sure you have the numbers 1 4 configured into a hopper Never assign the same number to multiple feeders Set unused hoppers to 0 will hide them on the recipe page You should configure the blender to match the actual physical location of each hopper to make it easier on the operator However this is only a visual issue and does not effect operation of the blender This screen also 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 EZ Mode then one hopper must be configured for Regrind and at least one hopper must be configured for Virgin material If this is incorrect a message will be given on the Recipe Screen You can configure as many Regrind or Virgin hoppers as you want Hopper Material Type tags are only used in EZ MODE BLN1 600A Chapter 7 Appendix 104 of 116 Advanced Alarm Options ADVANCED ALARM OPTIONS S Out of material retry limit for alarm surge Empty Delay O 01S BLE Osecs Unable to Make Rate Delay
23. The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment 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 minutes 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 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 1s 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 BLN1 600A Chapter
24. Verifying Calibration Recommended on a periodic basis to ensure accuracy l 2 3 4 BLN1 600A The blender must be stopped before this can be done From the Setup Menu touch Calibration and then Direct Scale Readout Remove the weigh hopper Locate the weight display for each of the two load cells Write down the displayed value Add the calibration weight to each load cell mounting bracket and write down the value displayed in weight as in step 4 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 during clean out Press X until you have reached the Recipe screen Chapter 3 Installation 47 of 116 Weigh Hopper Load Cell Calibration Recommended only if the calibration is out of spec x CALIBRATION x SCALE CALIBRATION Calibration Weight for LBS New Calibration 0 000 Load Cell Bits 0 0 Blender Must be Stopped First The blender must be stopped before this can be done From the Setup Menu touch Calibration and then Scale Calibration Enter in the scale calibration weight value stamped on the side of the weight The controller will prompt you to remo
25. disabled then every feed calculates a new Wt Sec value that is then weighted using the Weight Sec Filter in order to smooth out changes ABOVE BATCH SIZE FOR MAX WEIGHT ALARM This is the trigger point above the batch size that will initiate a Hopper Over Max Alarm This is designed to prevent the weigh hopper from being overfilled volume wise Care should be taken when adjusting the batch size of this parameter to make sure that they are appropriate BATCH DUMP SETTLE TIME Amount of time to weight after batch door is closed before taking weight snapshot LOADCELL SAMPLE TIME The sample time for each weight snapshot It is important that the mechanical settle time for each feeder be longer than WEIGHT FILTER LOADCELL SAMPLE TIME For instance if the defaults are used then you end up with 5 5 seconds 2 5 seconds Therefore 3 seconds is the absolute shortest settle time you can have for each feeder under MECHANICAL OPTIONS SIMULATION Simulation is only used for Demo purposes and should not be turned on for normal blender operation When enabled this allows a user to practice using the controller as if it were attached to an actual blender A PLC is required for this simulation PRINT WEIGHT DATA EVERY BATCH The blender s touch screen has a serial printer port that you can connect a serial ASCII printer to The data that is dumped to a printer 1s the same data shown on the Recipe Screen No averaging is done with the data shown to
26. factory preset at zero 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 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 control Experimentation with this setting can allow the operator to determine the best cycle for the material being weighed 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 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 Weigh Hopper Dump Cycle The dump cycle allows the weigh
27. now bit At this time you should then read the actual displayed weights values and record them into a log or chart If you are not getting the print now bit then refer to the blender manual to configure print batch data WHEN THE BLENDER IS NOT RUNNING THE TARGET VALUES GET SET TO 999999999 AND IN THE BEGINNING OF EACH BATCH ALL ACTUAL VALUES GET SET TO 999999999 UNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH INVENTORY EXPLANATION In order to keep track of very large numbers while accurately keeping track of small increments the blender uses two numbers for each inventory value One number is the whole portion of the inventory and the other is the decimal portion of the inventory in 3 decimal places Most people choose to ignore the decimal portion but it s there to provide additional accuracy An example is given below Whole portion value 12345 Decimal or Fractional portion value 678 This would represent 12345 678 Ibs or kgs BLN1 600A Chapter 7 Appendix 115 of 116 7 6 Technical Assistance Parts Department 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 ma
28. of batch Additivel 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 BLNI1 600A Chapter 4 Operation 63 of 116 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 e All ingredients are weighed as a percentage of the total batch 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
29. running recipe f39 16 8 R current hop6 recipe value L21 16 xxx xx recipe value for running recipe f39 17 9 R current hop7 recipe value L21 17 xxx xx recipe value for running recipe 39 18 10 R current hop8 recipe value L21 18 xxx xx recipe value for running recipe f39 19 HIDDEN RECIPE INFO THIS IS THE RAW RECIPE THAT WILL BE LOADED AT NEXT BATCH 1 R recipe entry mode n9 0 O percentage mode 1 parts mode 2 EZ mode 2 R batch size recipe value L21 9 xxx x lbs or kgs 3 R hopl recipe value L21 0 xxx xx recipe value for running recipe 4 R hop2 recipe value L21 1 xxx xx recipe value for running recipe 5 R hop3 recipe value L21 2 xxx xx recipe value for running recipe 6 R hop4 recipe value L21 3 xxx xx recipe value for running recipe 7 R hop5 recipe value L21 4 xxx xx recipe value for running recipe 8 R hop6 recipe value L21 5 xxx xx recipe value for running recipe 9 R hop7 recipe value L21 6 xxx xx recipe value for running recipe BLNI 600A Chapter 7 Appendix 112 of 116 10 R hop8 recipe value L21 7 xxx xx recipe value for running recipe 11 R recipe target total L21 8 xxx xx the is the total of hopl hop8 from above you must manually add this 1f you chose to skip the blenders error checking you must also ensure that you are in the correct recipe entry mode SEE BELOW FOR DETAILS TARGETS VS ACTUAL WEIGHT INFO 1 R print data now b3 1 11 read this tag and when i
30. 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 article 1910 147 and NFPA 70 and 79 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 Batch 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 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 motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on the Batch Blenders are primarily concerned with pneumatic and electrical power disconnection and the disabling of moving parts that may need to be
31. the Customer Targets vs Actual are actually what is in the batch BLN1 600A Chapter 7 Appendix 101 of 116 Feed Algorithm Options Screen FEED ALGORITHM OPTIONS P Double Gate EA Threshold Use Standard Algorithm Initial Target Under Over Limit Percent Limit O disable Batches for 10 Process Rate Process Rate EJ F ilter 3 INITIAL TARGET PERCENT This is the of target that the feeder will use to calculate the initial meter time of each batch for that feeder After the feeder has metered initially for a particular batch then this value is not used UNDER LIMIT Allowed underfeed of target weight for that feeder After the meter has completed the weight is observed If the weight is within the target by this amount then that feeder has completed metering and the blender moves to the next ingredient If it is not satisfied than the blender will repeat metering until this amount is reached The blender will retry forever or until the operator hits on the recipe page OVER LIMIT If after metering it is determined that a feeder has metered a value greater than the target Over Limit weight then a counter is incremented If this counter reaches the OVERFEED COUNT LIMIT Advanced Alarm Options Page then a OVERFEED ALARM will occur DOUBLE GATE THRESHOLD After a feeder has retried for this many retries then the GATE CYCLE TIME is temporarily doubled until the target is reached This is used as a preventative
32. the parameters which will best suit the auger size and gearbox ratio of the feeder To perform a feeder calibration the operator must enter the Feeder Calibration screen see menu structure select a feeder number then touch Press Here The feeder calibration will start automatically and will notify the operator when complete If the operator so desires they can repeat the process by entering in a new feeder number and touching the Press Here button If the blender does not see enough weight gain during the calibration process or if the weigh hopper reaches maximum weight then an error is given and the calibration is a failure Another useful feature on the Feeder Calibration screen is the ability to manually enter in the weight per second values This increases the blender learning process and the values can be recorded for future blending Alarm Setup This screen allows the operator to configure the alarm settings for each individual feeder It BLN1 600A Chapter 3 Installation 49 of 116 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 Retry the blender will not continue until it has metered the correct amount of material It continuously retries metering the ingredient until the target is satisfied It will retry forever under this condition The optional low level proximity switche
33. to load a stored recipe 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 e Ifrunning 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 Figure 38 Typical Batch Sizes Batch Size Ibs Inventory Shutdown In many applications the user of the Batch blending 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 the manufacturer has provided 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 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 Additional
34. 00A Chapter 5 Maintenance 77 of 116 5 3 Corrective Maintenance Electrical This section is designed to give the operator an overview of the electrical system that controls the Batch blending system Since the blender 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 advisable 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 Batch blender This section includes the following e Internal components of the control panel e Input signal to the control panel Output signals from the control panel Internal Components of the Control Panel e See Installation Packet supplied with unit for complete electrical schematics This section describes the internal components of the Batch 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 control panel The customer must supply 120 240 1 60 or 110 220 1 50 voltage via wires Ll amp L2 N Please insure that the earth ground connection is properly connected to an established earth ground e Power on is indicated by a lighted on off selector switch e Slide gate below mixer switch co
35. 1 of 116 Weigh Hopper Sub assembly Figure 60 Typical Weigh Hopper Assembly Parts List DESCRIPTION 2500 4000 6000 WEIGH HOPPER 872 00103 00 872 00104 00 A0770312 872 00229 00 872 00230 00 AIR CYLINDER 245 00003 00 A0770248 CLEVIS AIR CYLINDER 35460 35449 TUBING AIR TUBING NOT SHOWN A0770139 207 0002 1 00 4 FITTING AIR A0770126 35085K BLN1 600A Chapter 7 Appendix 92 of 116 Slide Gate Sub assembly Figure 61 Typical Slidegate Assembly Parts List DESCRIPTION 500 900 4000 6000 HOUSING DOUBLE DIAMOND 21 4 1 HOUSING SQUARE DIAMOND 21 4 Consult Factory HOUSING DOUBLE DIAMOND 45 6 GATE DIAMOND 71 4 A0770309 A0770305 872 00237 00 2 GATE SQUARE 21 4 NOT SHOWN 872 00116 00 872 00763 00 872 00236 00 GATE DIAMOND 5 6 872 00115 00 A0770309 872 00237 00 GUIDE ROD 1 4 A0770311 A0770307 GUIDE ROD 5 6 832 00015 00 A0770311 eee AIR CYLINDER 1 4 35448 a AIR CYLINDER 5 6 245 00006 00 i S CLEVIS AIR CYLINDER 1 4 35449 gt CLEVIS AIR CYLINDER 5 6 35460 bii bad 6 FITTINGS AIR CYLINDER A0770136 35086K 7 STROKE LIMITER 71 4 822 00966 00 A0770306 822 00997 00 STROKE LIMITER 5 6 822 00946 00 A0770310 BLN1 600A Chapter 7 Appendix 93 of 116 Knife Gate Sub assembly HD Optional Figure 62 Typical Slide Gate below mixer Assembly Parts List DESCRIPTION 50 90 250 400 600 4 FLANGEADAPTER Y
36. 20 1 xxx xx write your new recipe here 5 RW pvl hop3 temp recipe value L20 2 xxx xx write your new recipe here 6 RW pvl_hop4 temp recipe value L20 3 xxx xx write your new recipe here 7 RW pvl_hop5 temp recipe value L20 4 xxx xx write your new recipe here 8 RW pvl hop6 temp recipe value L20 5 xxx xx write your new recipe here 9 RVV pvl hop7 temp recipe value L20 6 xxx xx write your new recipe here 10 RW pvl hop8 temp recipe value L20 7 xxx xx write your new recipe here 11 R pvl recipe error message n9 2 1 total not 100 2 feeder type error 3 entry over 100 12 R pvl accept recipe enabled b3 0 4 this bit goes high if a new recipe is valid 13 RW pvl accept recipe requested b3 0 6 toggle this bit to accept a valid recipe you must also reset this bit after completion CURRENT RECIPE INFO THIS IS THE RECIPE THAT IS CURRENTLY BEING MADE 1 R current recipe entry mode n9 1 0O percentage mode 1 parts mode 2 EZ mode 2 R current batch size recipe value L21 20 xxx x lbs or kgs f39 36 3 R current hopl recipe value L21 11 xxx xx recipe value for running recipe f39 12 4 R current hop2 recipe value L21 12 xxx xx recipe value for running recipe f39 13 5 R current hop3 recipe value L21 13 xxx xx recipe value for running recipe f39 14 6 R current hop4 recipe value L21 14 xxx xx recipe value for running recipe f39 15 7 R current hop5 recipe value L21 15 xxx xx recipe value for
37. 85 of 116 7 1 Drawings and Diagrams Final Assembly Figure 55 Typical Final Assembly Parts List 500 90 250 4000 A0771710 A0771723 N A Description Mixer Assembl 2 Component Hopper Assembly DM DM 2 Component Hopper Assembly DM SQ 2 Component Hopper Assembly SQ SQ 3 Component Hopper Assembly DM DM DM 3 Component Hopper Assembly DM DM SQ 3 Component Hopper Assembly SQ DM SQ Removable Hopper Small Removable Hopper Large Slide Gate Assembly Major DM DM Slide Gate Assembly Minor DM DM Slide Gate Assembly Major DM SQ Slide Gate Assembly Major Single DM Slide Gate Assembly Minor Single DM Un 892 03271 00 892 03021 00 892 04554 00 892 03272 00 892 04622 00 N A 892 03275 00 892 02239 00 N A 892 02411 00 N A A0771708 A0771708 A0771701 A0771709 A0771709 Slide Gate Assembly Major Single SQ A0771702 Valve Stack Assembly 4 Comp N A A0771868 Valve Stack Assembly 6 Comp N A A0771869 Main Controller 892 01811 00 Main Display Not Shown Main Display Cable 8 ft Not Shown Calibration Weight Not Shown 822 00151 00 822 00153 00 Hopper Support Straps 872 00246 00 Louvers Hopper Covers DM Diamond SQ Square N A N A N A N A A A A A A A N N N N N N E 6 EX 8 NN 10 A 10 BLN1 600A Chapter 7 Appendix 86 of 116 Mixer Sub Assembly oh aly Chapter 7 Appendix 87 of 116 BLNI 600A Figure 56 Typic
38. ATCH ACCESS DOOR SIGHT GLASS OPTIONAL IF EQUIPPED HOPPER LOW LEVEL SENSOR OPTIONAL IF EQUIPPED HOPPER DRAIN TUBE WITH MANUAL SLIDEGATE BLN1 600A Chapter 2 Functional Description 17 of 116 Slide Gates Air operated slide gates are provided to meter the majority of pellet ingredients on Slide Gate blenders e The metering range assumes 1 8 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 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 The unique diamond gate provides a constant aspect amp opening that remains square regardless of the E stroke length of the cylinder This design o E asl provides a wider cross sectional opening when DIAMOND GATE 1 2 CLOSED approaching a closed position and provides better flow of plastic pellets out of the opening DIAMON
39. D 2500 SGBD 4000 SGBD 6000 SGA 012 SGA 030 SGA 060 CSG 150 CSG 500 CSG 900 CSG 2500 CSG 4000 _CSG 6000 ALL WEIGHT VALUES RECORDED IN POUNDS DIVIDE BY 2 20462 FOR KILOGRAMS ADVANCED WEIGHT OPTIONS Weight Filter Max Tare Offset Ibs Wt Sec Filter Weight sec Buffer Above batch size for max weight Time to settle hopper after batch dumped Loadcell Sample Time ms Simulator Weight Data Printing FEED ALGORITHM OPTIONS Hop1 Initial of Target Hop2 Initial of Target Hop3 Initial 96 of Target Hop4 Initial of Target Hop5 Initial of Target Hop6 Initial of Target Hop7 Initial of Target Hop8 Initial of Target Hop1 Allowed Underfeed Ibs Hop2 Allowed Underfeed Ibs Hop3 Allowed Underfeed Ibs Hop4 Allowed Underfeed ibs Hop5 Allowed Underfeed ibs Hop6 Allowed Underfeed ibs Hop7 Allowed Underfeed Ibs Hop8 Allowed Underfeed Ibs 45 5 500 Simulator off Print Weight Data Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Main 0 15 or Additive 0 03 Double Gate Threshold 5 Feed Algorithm Use Standard Algorithm Batches for process rate 10 Process Rate Filter 3 get 96 and Allowed Underfeed values assume stroke limiters installed in hoppers 2 amp 4 amp 5 thru 8 Gate Cycle Time values assume stroke li
40. D GATE CI OSFD A ANVARNING Slide gates create a pinch point hazard ZA WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning any blender including all Batch models Failure to do so may result in serious injury BLN1 600A Chapter 2 Functional Description 18 of 116 Figure 6 Typical Slide Gate Assembly STROKE LIMITER Each of the diamond gate air cylinders is actuated by a solenoid valve which are controlled by the blender PLC When the solenoid 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 e If the blender is in metering mode with one of the slide gates open do not open the front door of the blender e 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 Weigh Hopper On a Slide Gate blender the weigh hopper rests on each side on a precision cantilever load cell To remove the weigh hopper disconnect air line then lift the hopper from the bottom hold the dump door closed and slide it out once clear of the locating tab on the bracket above the load cell Once the hopper has been cleaned repos
41. Gravimetric Slide Gate Auger Batch Blender Red Lion Display Models BD CSG SGBD Part Number 882 02148 00 Bulletin Number BLN 1 600A Effective February 1 2013 Write Down Your Serial and Software Revision 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 2013 All rights reserved Shipping Info 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 prepaid write us for a receipted tr
42. Knife Gate Sub assembly HD Optional esses 94 Knife Gate Sub assembly RD Optional cesses 95 Control Panel EayQUt uu i ride e t bb n a uci aate va buda bes padaius 96 opareP arts IS ose nt ex pute Umi uicem AE ee oe OU ene 98 Addendum Service Supervisor InfoOrmation cccccccesceeeeceeeeeeeceeeseeeseeeseeeseeeteeees 99 Programmable Seting immenses de reed aset ansa pde se teu oven ptu te guteda dees 100 Advahced oetub MON nacimiento t rr Meo de deett at a matos 100 COMMUNICATIONS AND WEB SERVER esses nennen 109 LOGHMNICAlASSISIAN CO ee ME 116 Fans TIC AIT OIE ei nat E aw menu ns dA E cMSUS qud 116 Sales and Contracting Department esses enean nnn nnns 116 e c 116 VI Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your 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 m
43. Machine Tool asd IDI INCAND pee EEA 37 370VA 19 138VA 61W 5W Mixer Motor Amp Rating Starting Current Starting Current Part Number om FLA 230VAC FLA 115VAC 230VAC 115VAC BLN1 600A Chapter 7 Appendix 97 of 116 1 3 Spare Parts Kits Figure 66 Blender Spare Parts Listing Spare Parts Kits BD CSG SGBD A Kit Consumables A0574120 A0574134 A0574137 A0574125 A0574140 A0574143 Load cell assembly 72400767 00 724 00768 00 724 00770 00 724 00771 00 724 00772 00 H H Mixer high level sensor A0556548 B Kit Minimal Downtime A0574141 A0574144 All A kit parts A0574140 A0574143 Slide Gate Air Cylinder Majors 48 85448 SEY 245 00016 00 Slide Gate Air Cylinder Minors 245 00016 00 C Kit 24 7 Operation or International A0574122 A0574136 A0574139 A0574127 A0574142 A0574145 All A and B Kit Parts A0574121 A0574135 A0574138 A0574126 A0574141 A0574144 Second Load Cell Assembly w o plug 724 00767 00 724 00768 00 724 00770 00 724 00771 00 724 00772 00 Mixer Motor Protector overload A0558252 A0558255 Calex Module 724 00117 00 720 00002 00 720 51354 00 en 160 00280 00 51415 872 00101 00 872 00102 00 872 01716 00 872 01470 00 832 00030 00 A0771704 A0771705 A0771868 A0771869 Parts list for current blender software Rev 6 1 or higher Consult factory for Pre 6 1 software blender BLNI1 600A Chapter 7 Appendix 98 of 116 7 4 Addendum Serv
44. O DISSBLE RUN on HOPPER OVER MA OVERFEED Batch ao Delay OVERFEED Count E Limit OUT OF MATERIAL RETRY LIMIT FOR ALARM the number of retries before an out of material alarm is given The blender also uses the gain in weight to determine this but in the case where the weight change wasn t enough this is used to catch the Out of Material condition Low Level prox switches can also be used to give the earliest indication SURGE EMPTY DELAY the number of seconds before triggering a Surge Hopper Empty Alarm This is an optional feature and doesn t necessarily represent the blender s surge hopper Typically this can be used to indicate the take off box below the blender is empty UNABLE TO MAKE RATE DELAY if the high level prox hasn t been covered after this amount of time then an alarm is given indicating that the blender cannot keep up OVERFEED BATCH DELAY the number of batches allowed upon starting the blender before examining for an overfeed condition OVERFEED COUNT LIMIT the number of overfeeds that must occur before an alarm RUN STOP ON ALARM BUTTONS determines if the blender should continue running or should stop when these alarms occur If the blender is stopped due to an alarm condition then the alarm will stay active until the operator silences it IO Options io OPTIONS This page is used to configure optional alarm inputs The options are HOP6 low level or Mixer instant close feature used with metal sep
45. UM SCI CON aa sessio mte tl aia detectem e e cn Edd 30 Mezzanine and Floor Stands cccccccccscsseccuscecccensencnsnseeceusssetsessesensntenseusnenseussass 30 HD Heavy Duty RD Regular Duty nee E EEE 31 Regrind Auger Metering R A M Hopper esses 31 Ad gitive Feeder HopDOF meta tidie at abused uad adu bevus eese acp dpt dy due deu pe dus 32 LakKesom COombartments sicot a e n Re DEB ve e IMPO ads eons 32 2 5 Safety Fealut6s oe oix eme obese eco seers e ees r 32 Safety Circuit Standard Ses mides e ada asta ound Muti a parar talls 33 Fall Sale OE ra ON eco emma oci GOS 33 Safety DEVICE EOCIRCOQU S vesccoasciesaunnswindhdosaticsvad ahadentendalan eausa uode lace ec use dies 33 Twist Cap Plug Connected to Each Feeder Auger Motor 34 CHAPTER 3 INSTALLATION cinisme 36 3 1 Uncra ng the EQUIPMENT essi eoe tea epe o Ae Ene e aee ae Fx eb eade e vos Uode ve da cepe eu 36 3 2 Mechanical InstallallOri iu eee eto e ede eU sere india ace me tasses clic 36 Y Hicei mee cm 37 Mounting CORNGUIAUIONS ei ci a A E A hehe 37 Ma AMIN IO LIME eina iticabavite iohinteasgp MORI Ce aten is esto Matteo ial 37 Mezzamhe Moti es sca o a a tete olde odds Sede os quud 38 Floor Mount Central BICnder rerna 39 3 9 Blectical Connections 5 eros venden aate ln ixi fva atta da utc es vex NUR Tau UR suche d LOMA 39 3 4 Pneumatic Connections ssseseesssssssssssseseeesen ene
46. 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 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 In addition to the safety devices listed above these blenders are equipped with a line cord plug Shown in figures 17 and 18 This allows the operator or maintenance personnel to unplug the unit from its power source and tag it out The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores BLNI 600A Chapter 2 Functional Description 33 of 116 Figure 17 Electrical Disconnect Plug PUWE RECEPTACLE before servicing WO NOTE ISCONNECT POWER WHEN EANING 2 SERVICING ENDER Twist Cap Plug Connected to Each Feeder Auger Motor The cap plug must be turned counter clockwise to loosen and the female end of the cord removed from the motor plug This
47. age e 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 ACAUTION on an blender In addition cover or tie back long hair 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 is not in use Turn the switch to the OFF position or unplug it from the power source BLN1 600A Chapter 1 Safety 12 of 116 ACAUTION 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
48. aintenance 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 commencing with operation of the 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 blender 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 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 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 perso
49. al Mixer Assembly Parts List DESCRIPTION 500 0 2500 4000 6000 FRAME 872 00093 00 872 00094 00 A0770301 872 00224 00 FRAME EXTENSION NOT SHOWN 872 00208 00 872 00225 00 TOP PLATE 872 00095 00 872 00096 00 A0770300 872 00226 00 a ear DES EES 872 00097 00 872 00098 00 A0770316 872 01318 00 6 COUPLING AGITATOR DRIVE 8320001000 832000300 832 0018100 8 DRAWER SUPPORT 832 00011 00 077020 832 00034 00 9 BUSHING AGITATOR 832 00012 00 A0770319 832 00238 00 LOADCELL TWO 724 00767 00 724 00768 00 724 00770 00 724 00771 00 724 00771 00 WEIGICHOHPHER ACCESS DOOR MIXER 832 00013 00 832 00014 00 A0770303 832 00035 00 832 00036 00 DOOR CLIPS 09990 SAFETY COVER MIXER FRONT DOOR LATCH 35454 SUPPORT BRACE MIXER DOOR 872 00110 00 A0770332 872 00233 00 SAFETY COVER MIXER BACK 872 00111 00 872 00112 00 A0770302 872 00234 00 P angle reducer BLN1 600A Chapter 7 Appendix 88 of 116 Hopper Sub assembly Figure 57 Typical Hopper Assembly Parts List DESCRIPTION 50 90 0250 400 600 3 COMPONENT HOPPER sen 00096 00 MEM CN Consult Factory UNIO RAD AANA 2 DRAIN W MANUAL GATE ESC em SHOWN A05771782 OPTIONAL 3 DRAIN W MANUAL GATE NOT SHOWN A0771783 OPTIONAL BRACKET LOW LEVEL fonus SENSOR NOT SHOWN nar A0556548 730 00024 00 BLN1 600A Chapter 7 Appendix 89 of
50. ansportation 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 Bill of lading Packing list Operating and Installation packet NANA A Electrical schematic and panel layout drawings M 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 shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions Storage and Handling Keep equipment in a clean dry location when storing handling Environment should not exceed 25 C to 65 C 13 F to 149 F with no icing Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 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 purch
51. arator HOP7 low level or Surge Hopper Empty Feature used to detect a low level anywhere HOPS low level or Mixer Failure Prox used to detect a mixer that has stopped turning BLN1 600A Chapter 7 Appendix 105 of 116 Password Setup PASSWORD SETUP SX Supervisor 3145348 Password Use this page to configure all passwords Diagnostic Data DIAGNOSTIC DATA SX TARGET vs ACTUAL Data for Last Batch TARGET ACTUAL LBS LBS g 3208 3208 J 0 600 0 500 d 0 128 0 000 This page is used to monitor target vs actual data for all feeders BLN1 600A Chapter 7 Appendix 106 of 116 Factory Default Parameters ALL 2 1 13 Keith Packard OS 014 OS 070 OS 100 BD 150 BD 900 BD 2500 BD 4000 BD 6000 OA 012 OA 030 OA 060 Model Number 308 405 SGB 900 SGB 3500 SGB 5000 SGDB 150 2080066 SGBD 900 SGBD 2500 SGBD 4000 SGBD 6000 SGA 012 SGA 030 SGA 060 CSG 150 CSG 500 CSG 900 CSG 2500 _CSG 4000 _CSG 6000 Blender Number Auto Print Inventory Auto Clear Inventory Auto Print Clear Interval Start Hour SCALE CALIBRATION DIRECT SCALE READOUT FEEDER CALIBRATION Hop3 wt sec with square gate Ibs Hop4 wt sec Ibs Hop5 wt sec Ibs Hop6 wt sec Ibs Hop7 wt sec Ibs Hop8 wt sec Ibs FEED CAL OPTIONS Hop1 Batch for feeder cal Hop2 Batch for feeder cal Hop3 Batch for feeder cal Hop4 Batch 96 for feeder cal Hop5 Batch for feeder cal Hop6 Batch for feeder cal Hop7 Batch for feeder cal Ho
52. ased 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 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 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 watranty terms ii Table of Contents CHAPTER E SAFEL ocre EE 7 151 CROW io Use This Manual 523 eeeicXsec tonne v Pep extet Re a ou o Pes T Safety Symbols Used in this Manual sessi eere nnn nnns 7 Te2 Wamnings and PRECAUTIONS Let desc timui iu eec er dee te venim tua d daos endis cota dite auda 10 MEL eene EMEN 11 General esponsIbIITy soot te asta te cece bo raten tnt m olot 11 Operator ResSbDOnDSIDIIDV siii iod bove a eon OD REV a ob eas ies Dope eases 11 Maint
53. been emptied from the mix chamber This time can vary due to material flow characteristics and the size of the batch that is programmed into the blender control Experimentation with this setting can allow the operator to determine the best cycle for the material being mixed BLNI1 600A Chapter 4 Operation 69 of 116 Continue Stop Running if Mixer Fails If the blender is configured with the Mixer Failure Detection option then the user can select if he wants the blender to alarm only or stop if the mixer movement is not detected during mixing Alarm Messages 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 During an alarm condition not only will a visual alarm show up on the screen but also an audible alarm will sound The operator can press OR on this pop up to hide the screen temporarily but if the alarm condition is still unresolved then the message and horn will reappear after a short delay The blender will log when the alarm event occurred and when the condition went away The following is a list of all alarm names and descriptions Hopper 1 8 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 8 Low Level This alarm indicates that a hopper with a low level prox sensor is low Surge Hopper Empty This alarm indicates that the surge hopper se
54. chaumburg IL 60173 Phone 86 8717 1919 DE E 2 Ed Ia ee Phone 1 847 273 7700 Fax 86 512 8717 1916 i Phone 91 21 35329112 Fax 1847 273 7804 Fax 91 20 40147576 Europe ACS New Berlin 2900 S 160 Street ACS Warsaw New Berlin WI 53151 UI Dzia kowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 BLN1 600A Chapter 7 Appendix 116 of 116
55. cket 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 8 If any other ingredients need to 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 9 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 ANVARNING The auger metering assemblies on Auger blenders can be removed after the hoppers above them have been drained 10 Clean the vveigh hopper and mixer assemblies on the blender using a vacuum cleaner The mixer agitator is removable for cleaning if desired 11 Reinstall any metering units that were removed from the blender during clean out 12 Reinstall the weigh hopper using care to center the hopper on the load cells on the weigh hopper bracket 13 Load the blender with new material 14 Restart the unit with the new recipe ANVARNING Always disconnect and lockout all e
56. connections to the panel Material sticks to the flapper of the weigh hopper and is not Increase the Dump Cycles setting in Mixer and Dump Setup PLC Module Loaded Weigh hopper occasionally overfills dumped Too much i a Increase the Mixer Dump Time in Mixer and Dump Setup the mixer TOC Del a Is Oe Dee mired Increase the Mixing Time in Mixer and Dump Setup thoroughly BLNI1 600A Chapter 6 Troubleshooting 81 of 116 Check the blender s scale calibration and verify that the batch hopper is not overfilling If the hopper is overfilling adjust your Recorded Inventory Totals Es 5 PP Sen don t match what I ve actually used batch size If this is 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 Stop the Blender and the Start it again This causes the blender to perform an automatic feeder calibration If this doesn t fix it then manually perform feeder calibrations and retest Check that the printer is a SERIAL printer If not then you will need to either get a SERIAL printer or purchase a SERIAL to PARALLEL converter Check printer communication settings under Panel View Config I m missing an Automatic Check that the date and time are set correctly on the Panel View Inventory Report Config Page Max Hopper Weight Exceeded Alarm continues to re occur Printer did n
57. d Dump Setup Operator Screen MIXER AND DUMP SETUP Mix Time Remix Time Dump Time Dump Delay Dump Cycles Mixer Dump Time 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 Re Mix Timer In some applications the Batch 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 mix cycle after each dump of the weigh hopper BLN1 600A Chapter 4 Operation 68 of 116 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
58. der Feed Algorithm Options Make small adjustments and retest Increase the Gate Cycle Time This is found under Feed Algorithm Options Make small adjustments and retest A EI es DOES GA Increase the Allowed Underfeed value under Feed Algorithm 2 4 times Options Decrease the Retries before Double Gate Time e Other service problems or questions can be answered by contacting the Service Department BLN1 600A Chapter 6 Troubleshooting 84 of 116 Chapter 7 Appendix Annex B Information The following design information is provided for your reference l eer D d al m D 11 12 13 14 EDs 16 17 18 19 20 21 2 23 24 2X 26 21 28 The machine is not equipped with cableless controls 30 BLNI 600A No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 C Maximum 104 F Humidity range 50 relative humidity Altitude Up to 1000m above sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal 1 e machine mounting Special installation requirements Clean dry compressed air 1 cfm a 60 psi 1 7 m hr 4 14 bar Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 The addition of an auger feeder RAM option for regrind will increase the electrical supply requirements of a standard blender Nominal supply voltag
59. 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 Disconnect plug before cleaning or servicing motors or augers Figure 18 Twist Cap Plug Unscrew and remove plug from motor Motor BLNI 600A Chapter 2 Functional Description 34 of 116 Figure 19 Electrical Safety Interlock Switch Located on mixer door INTERLOCK SAFETY SWITCH A unique electric safety switch ts used to shut off power to the blender any time the mixer door is opened Do not alter or tamper with this switch in any way Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing or cleaning the Batch Blender Failure to do so may result in serious injury No one but the person who installed the lockout may remove it BLN1 600A Chapter 2 Functional Description 35 of 116 Chapter 3 Installation 3 1 Uncrating the Equipment Batch Blenders are shipped mounted on a skid enclosed in a plastic wrapper and contained in a crate 1 Remove crate from around blender 2 Secure strap of proper lifting capacity to both lifting lugs See Figure 20 below Use approved safety straps or chains to lift the blender at the marked lifting points Lift blender until strap 1s taut 4 Remove bolts attaching bottom of blender to shipping skid bolt located unde
60. e 120 240 1 60 or 110 220 1 50 60 serial number tag Earth ground type TN system has one point directly earthed through a protective conductor Power source should include a neutral power connection Over current protection is supplied in the blender but additional protection should be supplied by the user NFPA 70 article 430 24 to 430 26 The plug on the power cord serves as the electrical disconnect device located 0 6m to 1 9m above floor Unit 1s not equipped with three phase motors Blender is not equipped with local lighting Functional identification Blender is equipped with an optional CE mark or UL label 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 Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver 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 control repetitive functions are automatic while the blender is operating An inspection report detailing the functional test is included with the blender Color coded harmonized power cord is sufficient for proper installation Chapter 7 Appendix
61. e Out of Material Retry Limit found under Feed Algorithm Options see manual I m not getting Out of Material Check the Alarm Flags amp Feeder Setup to see if the feeder is Alarms configured to give you an alarm Clean out the hopper and retest If this doesn t fix the problem then perform a scale calibration Also check to sure that the Calibration Weight Exceeded 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 First check that the displayed actual dispensed weight is accurate If this 1s OK then check to see if the hopper is properly vented To do this fill hopper and turn off the loader and retest The feeder calibration values are moving too much BLNI 600A Chapter 6 Troubleshooting 83 of 116 This Is caused by the difference in bits not being large enough Using the 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 I can t calibrate the Scale without an error message Do other feeders calibrate correctly Is the feeder I m trying to calibrate a large gate If these are true then lower the Batch for Feeder Cal setting under Feed Calibration Options This can be I can t calibrate the feeder observed by looking at the Hopper We
62. e green arrow b After you have entering all values push the Accept New Recipe icon e The blender only shows the accept new recipe icon if the recipe is valid e Recipes can also be changed while the blender is running The new accepted recipe is loaded 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 Existing Recipes 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 by performing the following steps l 2 d 4 Touch the Recipe Book icon located on the Recipe Screen Select a stored recipe by changing the number next to Recipe Touch the load recipe icon Touch the accept new recipe icon e To edit save a recipe to the Recipe Book BLNI 600A Go to the Recipe Book by touching the Recipe Book icon Select a stored recipe by changing the number next to Recipe Make desired changes to the stored recipe Touch the save icon and wait for it to disappear vi Chapter 4 Operation 55 of 116 4 2 Operation Procedures The objective of this section is to familiarize the reader with the Slide Gate 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
63. edit the entire recipe book from your computer and then return this CompactFlash to your blender to synchronize it with the blender s recipe book The card must then remain installed This would allow you to copy the same recipe books to all of your blenders It is also possible to simply edit the stored recipes from the recipe book on each blender If you have purchased the USB Jump Drive option then you can place the recipes csv file you have modified onto any USB Jump Drive Then that drive can be inserted into each blender and the recipe book on each blender will automatically be updated This is the easiest way to perform a mass edit of all your blender s recipe book ACS ere Group EZ Mode Touch arrows to Touch here to close the R ec Rook If you ve modified a ii E icon Batch Size 4 0 0 00 REG Inventory Shutdown Value REQUIREMENTS FOR A VALID RECIPE Regrind hopper cannot be over 100 TA Moge Multiple Virgin hoppers must total 100 Recipe Total must add to 100 All entries are valid BLN1 600A Chapter 4 Operation 58 of 116 Cleanout Mode ACS Group EZ Mode BLN1 600A Chapter 4 Operation 59 of 116 Inventory Page ACS Group EZ Mode C BLN1 600A Chapter 4 Operation 60 of 116 Recipe Entry Formats The Batc
64. enance Responsibility cessitats temes e pana tops eua Ren daba bay teet es 13 Reporting a Safety Defect ccccccccsccsssccsscnsccssecnsecnsuecsuecsuecneceesesenenesessanessneaes 13 CHAPTER 2 FUNCTIONAL DESCRIPTION 14 2 1 Models Covered in This Manual cccccceeccecceeeseeeeeeeeceeeseeceeesseceeeseeteeeeeeteeneeees 14 2 2 General DESCrDUO eis enteniment teri rine metil le oder esrb pP n eva pe man mides 14 ACCOSSOlIQS aeos cleri Rat teense eis dietas uoto ured od aug tag a et d touto equ sE Cute 14 C UStOMEr SEVICE iaia mate maletes dall s cep e atu y eoa ant ed eh eu atn 14 2 3 Typical Features and COMPONENMS cccceccceccseeseeceeeseeeeceeeceeeeueceeesseeeeeeeeteeeeeeees 16 Mechanical Features ion E pads Ups acax d utaus Rand bosse usu 16 Controller FeatUl Gs uicta Mtas Yeah she ho idu gies adu uns le todas 16 System Component Description ssessssssesssssseee essen nnne nn nnns nna 17 SUPPI HOPPETS tat emus uM PEE MI IE ME 17 SEC OO NE Sais alat Out Net AO M LM E pre taeda see 18 We BOD Detectat lla lt ets 19 Mix CG RE T T TT 2 Operator Control Panel Display ise iier ote Eee et tema tintes 22 21 Optional Gompotenls eost deua eee te So posta n d ca erede retento p v dudes Febr ed Ld aa 30 Pneumatic Slide Gate below Mixer ccccccccecseccncceeceecseeceecsuenesseectesseensessnenens 30 LoW bevel GellsOks ou es t et Rad m EU rH UM d mE 30 Isemote TO
65. ered weight in batch xxx xxx f39 35 CUSTOMER FREE STORAGE SPOTS use for anything 1 RW customer free spot f42 0 2 RW customer free spot f42 1 BLN1 600A Chapter 7 Appendix 113 of 116 Alarm Number Explanation The alarms are given in individual bits and are reflected in the alarm number The alarm number is only used to drive a pop up message and will probably not be very useful to you If you decide to use the alarm number instead of reading the individual alarm bits then the related values are shown below N11 74 Value Alarm Descriptions 0 NO ALARM l HOPPER 1 Out of Material l 2 HOPPER 2 Out of Material 2 3 HOPPER 3 Out of Material 3 4 HOPPER 4 Out of Material 4 SS HOPPER 5 Out of Material 5 6 HOPPER 6 Out of Material 6 T POWER INTERRUPTION while metering a Batch 8 PLC BATTER LOW Check PLC and Configure the Blender 9 PLC MODULE LOADED Turn Off Unit Remove Module then Configure the Blender 10 MAX HOPPER WEIGHT EXCEEDED CHECK BATCH SIZE 11 CALIBRATION ERROR Clean out weigh hopper and check calibration 15 HOPPER 1 Low Level 16 HOPPER 2 Low Level 17 HOPPER 3 Low Level 18 HOPPER 4 Low Level 19 HOPPER 5 Low Level 20 HOPPER 6 Low Level 21 HOPPER 7 Low Level 22 HOPPER 8 Low Level 23 HOPPER 7 Out of Material 24 HOPPER 8 Out of Material FIXED DECIMAL EXPLANATION All weight values and recipe values use fixed decimal This must be taken into consideration when writing or reading val
66. erial 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 Printer Features The Batch blending system may be equipped with a printer so a printer menu is available to the operator This menu is displayed in the Report Setup area of the Setup screen The printer menu is accessed by pressing Report Setup from the Setup menu Figure 50 Typical Report Setup Operator Screen REPORT SETUP RX Blender Number 1 9 Enable Disable the utoprint amp Auto Sutoclear Inventory Disabled Auto Report interval hours PEE Auto Report Start Hour 0 23 midnight 0 IES The blender can be configured to automatically print and clear inventory on a selected interval To automatically print or clear reports perform the following 1 Enter in the Report Interval in hours 1 24 2 Enter in the Report Start Hour 0 23 0 is midnight 3 Enable Auto Print Inventory and Auto Clear Inventory The user can select to only print the inventory on an interval if so desired by not enabling the Auto Clear Inventory feature The user should also enter in the blender number which will identify the blender that the printout came from The printed inventory might not match the percentage shown as the percentage shown is the actual blender percentage running the current recipe The inventory depending on when it
67. es horizontal and vertical pressures ACAUTION to the mounting flange If there is a question as to the mechanical stability of a mounting flange contact the manufacturer 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 Figure 21 Typical Mezzanine Mounted Batch Blender 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 _ GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMER EXTRUSION CONTROL USED WITH RE LOAD VALVE PURCHASED SEPARATELY tU RV RR RE RR RE RE RNR TUR m e 3 BLN1 600A Chapter 3 Installation 38 of 116 Make sure that adequate space is around the blender 36 recommended to allow proper cleaning servicing etc Floor Mount Central Blender 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 Slide Gate blender into place e The blender must be securely fastened to the floor before operating ACAUTION e Manufacturer assumes no responsibility for any damages resulting from improper installa
68. estion as to the mechanical Stability of a mounting flange contact the manufacturer s engineering department 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 BLN1 600A Chapter 3 Installation 37 of 116 e 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 e Larger blenders need to be braced as part of the installation Take care to insure proper orientation with adequate access to operator controls mix chamber and metering units e Never weld on the blender support stand machine or mezzanine without first removing the control panel and verifying that the blender is properly grounded Mezzanine Mount In a mezzanine mount application review the following items before installation begins First verify the Batch mounting locations match the mezzanine supports Verify that the mezzanine is capable of supporting the blender with a full load of material and vacuum loading equipment installed e While in operation the batch blender appli
69. eted the current batch Weigh hopper closed Weigh hopper open Mixer not full Mixer Full Mixer Knife Gate Closed Open Ingredient Feeding Ingredient Alarming Accept Undo Recipe Change BLN1 600A Chapter 2 Functional Description 24 of 116 Entering a Recipe ACS 1 Group EZ Mode REQUIREMENTS FOR A VALID RECIPE Regrind hopper cannot be over 100 PA Moas Multiple Virgin hoppers must total 100 Recipe Total must add to 100 All entries are valid BLN1 600A Chapter 2 Functional Description 25 of 116 Recipe Book ACS Group EZ Mode Touch arrows to Touch here to close Batch Size 4 0 A Ar 2 UU RA nen RII E Inventory Shutdown Value REQUIREMENTS FOR A VALID RECIPE Regrind hopper cannot be over 100 pews Multiple Virgin hoppers must total 100 Percentage Mode Recipe Total must add to 100 All entries are valid BLN1 600A Chapter 2 Functional Description 26 of 116 Cleanout Mode ACS Group EZ Mode BLN1 600A Chapter 2 Functional Description 27 of 116 Inventory Page ACS Group EZ Mode C BLN1 600A Chapter 2 Functional Description 28 of 116 Inventory Shutdown Event The blender has a feature called inventory shutdown This is typically used to fill gaylords without the need of a f
70. h blending system contains several operator friendly recipe menus This section of the manual lists these recipe menus Recipe Page Start Setup Recipe Book Page Recipe Format Upon Start Up the blender controller will default to the Recipe 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 EZ Recipe Mode Percentage Mode or Parts Mode EZ Recipe mode is the default setting preset at the factory RECIPE FORMAT S ACS SETUP Group ERO EU AU o id 12345676 TIES 8 40 Inventory Shutdown value o Recipe Format Menu EZ Recipe Percentage or Parts e Metering Order Always make sure all 8 hoppers are entered Batch Size only use batch sizes appropriate for your blender too small will cause inaccurate blending Inventory Shutdown used to shut the blender down after making a certain amount Batch ready mode blender will hold a completed batch in the weigh hopper e Weigh every batch options determines if every batch is weighed e Change recipe without Stopping if set to Stop Blender before Changing Recipe then the operator does not need to touch the accept recipe icon after editing the recipe The drawback is that the recipe cannot be changed on the fly The Recipe Format screen allows t
71. he user to change many parameters concerning the way that the recipe is entered by the operator It is accessed by touching the manufacturer s 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 on the next few pages BLN1 600A Chapter 4 Operation 61 of 116 EZ Recipe Mode Most common in injection molding The EZ Recipe menu structure allows recipes to be entered and adjusted by touching the buttons on the panel face for 1 to 6 components In this mode hopper 1 is configured as virgin hopper 3 is configured as regrind and the others are configured as additives 1 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 based 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 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 The 1 hopper NAT Virgin Material
72. his 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 Weigh Every Other Batch Feature This setting allows the operator to only weigh selected batches The operator can choose from the following Weigh Every Batch Weigh Every Other Batch Weigh Every Third Batch Weigh Every Fourth Batch Weigh Every Fifth Batch and Never Weigh Ifa batch is timed instead of weighed then all components run concurrently instead of one at a time This dramatically increases the maximum blender rate but introduces error into the timed batches Because the ingredients are not weighed error is introduced into the Inventory Totals Each timed batch is assumed to be perfect and these perfect dispensed amounts are added to the Inventory Totals BLN1 600A Chapter 4 Operation 66 of 116 BLNI 600A Every Batch This mode of operation weighs every component of every batch that is metered by the Batch blending system Every Other Batch First batch weighed Second batch is metered based on the metering times of the first batch Every Third Batch First batch weighed Second and third batches are metered based on the metering times of the first batch Every Fourth Batch First batch weighed Second third and fourth batches are metered based on the metering times of the first batch Every Fifth Batch First batch weighed Sec
73. 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 material that may cling to the dump valve To enter the dump cycle menu first enter the Setup menu by pressing the Manufacturer s 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 in section 3 5 Mixer Dump Time The mixer dump time is the amount of time the knife gate below mixer s valve remains open to allow blended material to exit the blender To view and change the current mixer dump time settings enter the Setup menu and select the Mixer and Dump Setup screen Press the field next to Mixer Dump Time to set the operation of the Dump Valve The timer should be set to close the dump valve shortly after all material has
74. 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 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 A complete listing of all default values is provided at the end of this manual Touch here and enter BLN1 600A Chapter 3 Installation 44 of 116 BLNI 600A Recipe Page Start Change Recipe Values by touching the number you wish to change Touch Accept New Recipe button after you ve made the desired changes Touch Undo button to cancel a recipe change before accepting it Start or stop the blender by touching the Push to Start or Stop button Access Recipe Book Page Access Clean Out Mode Access Inventory Page Access Setup Page Lock Unlock User Interface Menu Structure for Batch Blenders User Interface Lock e Lock the user interface to prevent others from making changes or viewing the blender Recipe Book Page Save the running recipe to the book e Create Edit a stored recipe e Load a stored recipe Return to the Recipe Page Clean Ou
75. ice Supervisor Information This section of the manual should not be used by untrained personnel blender controller and or program can be compromised 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 unit from operating properly and may void part or all of the warranty After all selections are made Keep pressing the X button until the unit returns to the Recipe menu Programmable features should not be accessed by 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 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 Information included in this manual is subject to change without notice Passwords e User Password 5413 Maintenance Password 31453487 BLNI 600A Maintenance password should only be supplied to qualified personnel The program can be compromised Chapter 7 Appendix 99 of 116 Programmable Settings The Batch blender software program has been designed to allow some customizing to achieve certain desired operating parameters The following is a listing of
76. ight display without an error message 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 Check the dump time setting It may be set too short Weigh hopper does not empty If this does not correct the problem clean the weigh hopper and completely recheck the scale diagnostics readout If not showing 0 zero when empty re calibrate the scale Verify application is not exceeding blender capacity Verify additive percentage is not higher than designed resulting in Blender does not make rate excessive dispense time Verify all materials are feeding freely through the metering gates or augers I have changed the recipe entry mode metering order batch size inventory shutdown weigh every batch mode or feeder type and alarm flags but the change hasn t taken place All of these settings are part of the current running recipe This makes it easy for the operator to load a stored recipe without having to reconfigure all of these parameters for the new recipe All you have to do is touch Accept New Recipe to load these values into the running recipe Check that the Gate Cycle Time is set correctly Try lowering this A feeder always puts too much value If it is then lower the Initial of Target to Meter These material in the batch are found un
77. 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 BLNI 600A Chapter 1 Safety 10 of 116 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution 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 every day safety is 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
78. in when they want to begin the timed printouts Simply select the time 0 23 midnight 0 on a 24 hour clock and press the Done key to retain the current settings in the Report Setup screen Batch Printout The target vs actual weight data for every batch can also be printed See Advanced Weight Options to turn this on off This feature uses an excessive amount of paper and should only be used for trouble shooting Print Inventory The print inventory menu item is used to produce on demand inventory printouts Before selecting this item be sure that the printer is properly connected and ready This function will generate an inventory printout with the current date and time information Display Time and Date The display Time and Date item in the upper right corner of the Report Setup menu is used to verify the current time and date information Color Changes The color change procedure is meant for use with the basic Batch Blender This procedure assumes that the color component of the blend is in an additive ingredient hopper 2 4 5 or 6 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 clea
79. ipe format should be in EZ Recipe mode Pressing the highlighted box on the feeder number the operator can enter a valid recipe or use a previously stored recipe from the recipe book 1 The blender is started by turning system on or material dropping below level switch in mix chamber 2 Metering gates are opened or auger motors are turned on to meter material into the weigh hopper in the programmed order 3 Each component is weighed then the batch is dumped into the mix chamber provided the mixer High level switch is not covered 4 The material is mixed in the mix chamber and flows into the processing machine 5 The optional slide gate below the mixer may control the flow of material to the molding machine or extruder BLNI1 600A Chapter 4 Operation 54 of 116 Quick Start Procedure New Recipes I Verify the weigh hopper calibration before running the blender page 47 2 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 e Hopper 3 on some models is equipped with an oversized square gate to assist in the feeding of the regrind material 3 Enter the recipe menu on the touch screen by turning on the touch screen controller It will automatically default to this screen and enter the blend recipe desired following the steps listed below a Touch the hopper and enter a new value 0 to 999 99 then hit th
80. isplay operator control panel with 8 cable Target vs actual set point verification nventory accumulation for all ingredients Audible and visual alarms Auxiliary alarm contact BLN1 600A Chapter 2 Functional Description 16 of 116 e 100 recipe storage book Three 3 types of recipe entry procedures available o EZ Recipe mode up to 8 component recipe entry Color and additives are metered as a percentage of the virgin material o Percentage mode recipe entry Ingredients are metered as a percentage of the overall batch o 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 Serial printer and communications ports System Component Description This section describes the various components of the blending system 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 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 Many hoppers are equipped with a sight glass and or access door Figure 5 Typical Hopper Assembly DOOR L
81. ition it onto the load cell brackets using care not to damage the load cells Position the hopper as close to the center position between the load cells as possible e Use care when replacing the weigh hopper since the load cells are delicate ACAUTION vveighing 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 e Load cells if damaged will have to be sent back to the manufacturer for testing and evaluation BLN1 600A Chapter 2 Functional Description 19 of 116 Figure 7 Typical Weigh Hopper Assembly LOCATING TAB MOUNTING BRACKET AIR CYLINDER WEIGH HOPPER The weigh hopper dump door holds the material until it is dumped into the mixing section The cylinder is actuated by a solenoid in the valve stack on the side 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
82. larm 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 N O TI C E e The customer alarm contact is open if the panel control power is turned off This contact is for use with a customer supplied alarm device as described above e The alarm contact has a maximum load of 3 amps BLN1 600A Chapter 5 Maintenance 79 of 116 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend tha
83. ld not be concerned If the alarm continues to occur then the operator should have maintenance check the blender 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 BLN1 600A Chapter 4 Operation 70 of 116 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 would have been compromised since it did not finish the batch in progress 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 Module Loaded This alarm occurs after a software upgrade to the PLC The alarm instructs you to turn off power to the blender remove the Memory Module turn on power and then reconfigure the blender parameters 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 Ala
84. lectrical power and pneumatic i e compressed air sources prior to servicing or cleaning any product including all Batch blending systems Failure to do so may result in serious injury or death BLN1 600A Chapter 4 Operation 74 of 116 4 3 Shut down The Slide Gate Gravimetric Blender can be stopped in one of two ways l 29 To immediately stop the blender the operator can touch Abort Current Batch icon This will cause the blender to stop making the current batch immediately If the blender is stopped in this method then the current batch will not be completed properly 3 If the operator desires to complete the current batch of material then he can stop the blender using the selector switch icon The blender will finish the current batch of material before stopping BLN1 600A Chapter 4 Operation 75 of 116 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule 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 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 Date
85. lling operating or maintaining this equipment use good judgment and follow these safe practices i As A bs DQO Ay M Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions 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
86. ls Treated as Alarm Only or Out of Material Network Setup IP Address Subnet Mask Send Config to ENI Module Enable Ethernet Configurator Modbus Plus Aile Lina 45 of 116 Blender Calibration The load cells on the blender are FACTORY CALIBRATED Since the load cells can be subject to shock loading during shipping moving etc we recommend that they be recalibrated The load cells monitor the weight of each ingredient added to the blender weigh hopper Since load cells are reading the actual material weight that is metered by the feeders the proper calibration of these load cells is essential for the correct operation of the blender The load cells should be checked once a month with a calibration weight and if necessary recalibrated to ensure that they have not been damaged in the normal routine of removing and replacing the weigh hopper for cleaning color changes etc The calibration of each load cell is accomplished by using two reference 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 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 used in the load cell calibration procedure is a known amount of weight for the weigh ho
87. ly it will flash an alarm and wait for operator attention An example of this screen is shown below BLN1 600A Chapter 4 Operation 65 of 116 Typical Inventory Shutdown User Prompt Operator Screen Touch here after VOIDS CLETIEST LAG The blender has reached the Gay estar inventory shutdown amount and has been stopped Touch here to close EE EE CROWE je e ale 1 dissa marea ANA oa S Cnadvce an UI ACK Li j V C DOL U VACII Restart Stop Blender Blender 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 Batch Ready Mode 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 Auto Start Feature By enabling this feature the blender accurately finishes a batch that was interrupted by loss of blender power T
88. measure in the case the user has set the GATE CYCLE TIME too low for that feeder Mechanical Options Page BATCHES FOR PROCESS RATE The process rate on the Inventory Screen is the rate at which the customer is using the blend Since a batch blender does not have a loss in weight hopper to measure this take away rate then the process rate is only an estimate This value helps to improve that value This is the number of batches required before calculating the process rate The blender must hit high level at least twice and have made this number of batches before a rate will be calculated The error is always batch If you set this value to 10 then that means the process rate error will be 10 If you want to improve the error increase this value but this will delay getting a process rate number If set to 100 then the error would be 1 STANDARD VS ADVANCED ALGORITHM The blender should be set to Standard for most cases However if enabled you can meter in the first ingredient and then all other ingredients will be recalculated based on the actual meter of the first ingredient To do this you will need to lower the batch size by the you expect the first ingredient to be in error You must also increase the ABOVE BATCH SIZE FOR MAX WEIGHT ALARM by the same amount Doing this will lower your overall throughput capability of the blender but will increase accuracy by about a factor of 10 BLNI 600A Chapter 7 Appendix 102 of 116
89. miters installed in hoppers 2 amp 4 amp 5 thru 8 0 025 0 025 0 05 0 025 0 025 0 025 0 025 0 025 0 025 1 Loadcell 2 Loadcells 1 Loadcell Mixer Bump Time to Detect high level 0 25 Batch Mixing Mix Single Batches FEEDER AND TYPE SETUP CONFIGURE APPROPRIATE HOPPER NUMBERS ACCORDING TO ORDER AND MECHANICAL LAYOUT Hop1 Feeder Type VIRGIN Hop2 Feeder Type ADDITIVE Hop3 Feeder Type REGRIND Hop4 Feeder Type ADDITIVE Hop5 Feeder Type ADDITIVE Hop6 Feeder Type ADDITIVE Hop7 Feeder Type ADDITIVE Hop8 Feeder Type ADDITIVE ADVANCED ALARM SETUP Surge Hopper Empty Delay Out of Material Retry limit before alarm Unable to Make Rate Delay Overfeed Batch Delay Overfeed Count Limit Blender Factory Default Setup Parameters Group 2 1 13 Keith Packard F OS 007 OS 014 OS 070 OS 100 BD 150 BD 500 BD 900 BD 2500 BD 4000 BD 6000 OA 012 OA 030 OA 060 SGB 450 SGB 900 SGB 3500 SGB 5000 SGDB 150 SGBD 500 SGBD 900 SGBD 2500 SGBD 4000 SGBD 6000 SGA 012 SGA 030 SGA 060 CSG 150 CSG 500 CSG 900 CSG 2500 _CSG 4000 _ CSG 6000 ALL WEIGHT VALUES RECORDED IN POUNDS DIVIDE BY 2 20462 FOR KILOGRAMS Model Number 10 OPTIONS I O 7 used for Hop 6 Low Level I O 11 used for Hop 8 Low Level I O 10 used for Hop 7 Low Level PASSWORDS User Password 5413 Maintenance Password 3145348 LOADCELL CALEX MODULE DIPSWITCH SETTINGS Switches set to ON position 1 amp 2 SPECIAL NOTES 2 Component Blenders with R A M Consult Engineering
90. mply press the X exit If the order is changed then you will need to touch Accept New Recipe icon on the Recipe Screen before the change takes effect o BLN1 600A Chapter 4 Operation 64 of 116 This order can be changed while the blender is making a batch without affecting the current running batch e All feeders must be in the metering order If you enter an invalid metering order then the blender will default back to its original setting of 12345678 Batch Size The Batch blending system is a gravimetric 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 This feature allows the operator to change the size of the batch to be made A value will need to be entered between 0 5 to 99 9 This 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
91. n 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 off air to the blender circuit by deactivating the master air valve Then unplug the quick disconnect from the air BLN1 600A Chapter 4 Operation 73 of 116 supply hose to the blender to further ensure that no air pressure is supplied to the blender ANVARNING Always unplug the main power cord Always disconnect the air supply to the blender Prior to performing any operations inside any access areas of the blende where there are moving parts 6 Remove the weigh hopper by unplugging the air line disconnect fitting holding the dump door closed lifting the hopper to clear the load cell brackets and gently pulling the weigh hopper out of the blender To reduce the chance for damage to delicate load cells use care when ANVARNING lifting the weigh hopper off load cell locating tabs and when reinstalling the weigh hopper on load cell brackets 7 Ifyou 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 bu
92. nal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death A DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury ANVARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury ACAUTION CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage BLN1 600A Chapter 1 Safety 7 of 116 Figure 1 Safety Tags and Warning Labels Hazard Alert Symbol Description Explanation Pinch point slide gate Every month inspect the Hands can become shears blades for any type of entangled or cut if they wear For further information enter the danger zone of see the Maintenance Chapter gears or cutting shears in this manual High voltage inside Every six months inspect all enclosure The electrical electrical connections for enclosure is supplied with secure attachment For 3 phase electrical power further information see the Use caution when using or Maintenance Chapter in this maintaining this product manual Shear point rotating mixer Every month inspect the Hands can become shears blades for any type of entangled or cut if they wear For further information enter the danger zone of see the Maintenance Chapter gears or cutting shears in this manual Shear hazard rota
93. ng 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 assemblies Site Requirements This section describes site requirements in detail These requirements are broken down into mechanical mounting electrical connections and pneumatic connections Since the Slide Gate Blender is available in several different mounting arrangements it is necessary for the reader to become familiar with the different arrangements Mounting Configurations The Slide Gate Blending System is available in 3 three basic mounting arrangements They are e Machine Mount e Mezzanine Mount Floor Mount Machine Mount In a machine mounting application of the Slide Gate 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 Slide Gate blender flange if the optional pre drilled holes were ordered The Slide Gate blender 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 Slide Gate blending system with a full load of material and vacuum loading equipment installed e While in operation the slide gate blender applies horizontal and vertical ACAUTION pressures to the mounting flange If there is a qu
94. ns as the disconnect device See Figure 11 on Page 27 for an example 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 Pneumatic Connections The Batch 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 blender 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 e As this blender uses air for blender metering functions it is very important ACAUTION to supply clean dry air to the blender Dirty or oily 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 Also use a dedicated line to ensure proper air supply Figure 23 Customer Supplied Pneumatic Components BLENDER CUSTOMER SUPPLIED COMPRESSED AIR COMPONENTS DRY 60 PSI COMPRESSED AIR lt REGULATOR 5 MICRON WATER OIL FILTER SEPERATOR The manufacturer provides all pneumatic lines on the blender piped to a single 47 NPT standard pipe thread fitting The Batch blending system requires approximately 1 cfm 1 7 m hr
95. nsor is sensing a low level This can be any surge hopper and not necessarily related to the blender It is a customer specified alarm input Mixer Failure This alarm indicates that mixer movement was not detected when it was suppose to be This is only available if the Optional Mixer Failure feature has been added to the blender Unable to Make Rate This alarm indicates that the blender has not hit high level in an appropriate amount of time Hopper 1 8 Unstable Alarm This alarm indicates that a hopper has not stabilized This is determined by examining the last 3 feed calibration measurements while the blender is running If the 3 measurements are within a set deviation of each other than the hopper is stable and these measurements are used to average the feed calibration value If not then a counter is increased every batch and the feed calibration value remains unchanged After a set amount of batches that are not stable then an alarm is given Hopper 1 8 Overfeed Alarm This alarm indicates that a hopper has put too much into the current batch Max Hopper Weight Exceeded check batch size This alarm indicates that the weight in the weigh 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 shou
96. ntrols position of optional slide gate e Safety Active light displays status of safety interlock circuit Audible alarm horn alerts operator to blender fault BLNI1 600A Chapter 5 Maintenance 78 of 116 Input Signals to Programmable Controller The Batch 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 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 Output Signals from Programmable Controller The Batch 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 The auger motor outputs are driven from a control output from the PLC Each 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 a
97. nual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 North America emergencies after 50m CST 847 439 5855 Europe 48 22 390 9720 India Middle East 91 21 35329112 Asia Australia 86 512 8717 1919 Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you 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 and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe 48 22 390 9720 India Middle Ease 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information visit us at www acscorporate com United States Asia Australia India Middle East ACS Schaumburg ACS Suzhou ACS 1100 E Woodfield Road 109 Xingpu Road SIP age Gat No 191 1 Sandbhor Complex Suite 588 Suzhou China 215126 Mhal hakan Tal Kh S
98. o allow accurate weighing of the material Each component is metered in the order specified by the Metering Order setup See the Installation amp Setup chapter for further details 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 Page 58 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 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 BLN1 600A Chapter 4 Operation 71 of 116 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 controller that there is room in the mixing section to accept a batch of mat
99. oftware Rev 4 X or higher Consult factory for Pre 4 X software blender BLN1 600A Chapter 7 Appendix 96 of 116 PORTANT INFORMATION CONCERNING MAX BLENDING RATE LISTED e The standard maximum blending rate is based on a 3 component blend running 80 virgin 18 regrind free flowing and 2 pelletized color Each additional component reduces the overall maximum rate by 20 per component s Recipes with more than 50 regrind will significantly reduce the throughput and minor ingredient accuracy of the blender Consult the factory for achievable rates e Two component recipes may REDUCE overall blender throughput due to reduced available weigh hopper capacity Consult the factory for achievable rates 9 Rates are based on dry free flowing virgin pellets with a bulk density of 35 lbs ft Rates will vary as a result of the number of blender components the materials and the recipe s used Consult the factory for guaranteed rates 8 Material samples are required for testing prior to shipment for guaranteed rates Consult the AEC Sales Department for shipping instructions and for the amounts of each material to send for testing A test request form must be submitted Component Watt Rating 120 24 VDC AB Mitsubishi Allen Bradley 8 70VA 9 80VA 4PDT y 6A 24W 88 C43 C60 85 12VA 16 30VA Full Volt 3W 10 130VA 16 200VA 2 4A 50W Mitsubishi D110 D180 2DPT 1o Transformer 50W 37 370VA 37 370VA 1 2VA 16 30VA 1 5W D250 D300 37 370VA D600
100. ond third fourth and fifth batches are metered based on the metering times of the first batch Never Weigh Metering is based on Feed Calibration values only Loadcells are not used This is only used if you have a failed loadcell e Not weighing every batch sacrifices blender weighing accuracy but increases the blender s maximum rate Chapter 4 Operation 67 of 116 Mixer and Dump Setup 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 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 Batch 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 Figure 40 Typical Mixer an
101. op7 inventory L30 6 this is the whole portion of the inventory f39 9 entire number 10 R hop8 inventory L30 7 this is the whole portion of the inventory f39 10 entire number 11 R batch inventory L30 35 this is the whole portion of the inventory f39 11 entire number 12 R hopl fractional inventory L30 16 this is the fractional part of the inventory xxx 13 R hop2 fractional inventory L30 17 this is the fractional part of the inventory xxx 14 R hop3 fractional inventory L30 18 this is the fractional part of the inventory xxx 15 R hop4 fractional inventory L30 19 this is the fractional part of the inventory xxx 16 R hop5 fractional inventory L30 20 this is the fractional part of the inventory xxx 17 R hop6 fractional inventory L30 21 this is the fractional part of the inventory xxx 18 R hop7 fractional inventory L30 22 this is the fractional part of the inventory xxx 19 R hop8 fractional inventory L30 23 this is the fractional part of the inventory xxx 20 R batch inventory decimal part L30 39 this is the fractional part of the inventory xxx BLN1 600A Chapter 7 Appendix 111 of 116 RECIPE INFO THIS IS WHERE YOU RIGHT THE NEW RECIPE TO 1 RW temp recipe entry mode n9 11 O percentage mode 1 parts mode 2 EZ mode 2 R temp batch size recipe value L21 53 xxx x lbs or kgs 3 RW pvl hopl temp recipe value L20 0 xxx xx write your new recipe here 4 RW pvl hop2 temp recipe value L
102. ot print The blender intermittently dumps a batch of material with one or more of the components incomplete Check the recipe information ensure that both the percentages and batch size are set properly Blender occasionally dumps an incorrect batch 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 Check the mixer high level switch sensitivity When the sensor is covered 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 1s 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 Check the mixer high level sensor connection to the control panel Check the mixer high level switch sensitivity Fines may have coated the level switch it needs readjustment Blender will not batch with Check the proximity switch connection empty mixer Make sure that the recipe is correct Check batch size Blender keeps dumping after mixer is full BLNI1 600A Chapter
103. ouble slot on top of the gate assembly and secure it in place with the button head screw that is provided Be sure to use the lock washer to prevent the stroke limiter from coming loose Figure 24 Stroke Limiters BLN1 600A Chapter 3 Installation 42 of 116 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 Figure 25 Weigh Hopper THIS SIDE FACES FRONT OF BLENDER e THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE FROM FRICTION WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF Final Connections Connect the blender to the appropriate power source 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 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 e Make sure that the blender is supplied with clean dry 60 psi 4 14 bar compressed air BLN1 600A Chapter 3 Installation 43 of 116 Controller Set up This section describes the proper setup of the batch blending system control parameters These parameters are operator changeable
104. p8 Batch for feeder cal Hop1 Allowed Deviation for Stable Hop2 Allowed Deviation for Stable Hop3 Allowed Deviation for Stable 96 Hop4 Allowed Deviation for Stable 36 Hop5 Allowed Deviation for Stable 96 Hop6 Allowed Deviation for Stable Hop Allowed Deviation for Stable 96 Hop8 Allowed Deviation for Stable 96 Unstable Alarm Limit Mixer Dump Time w o knifegate set to 0 Continuous Timed Mixii ALL WEIGHT VALUES RECORDED IN POUNDS DIVIDE BY 2 20462 FOR KILOGRAMS EZ MODE QUICK SET MODE 12345678 2 0 4 0 B 0 0 Enabled Enabled Every Batch PERFORM A SCALE CALIBRATION ON ALL MANUFACTURED UNITS LOG THESE VALUES AFTER THE SCALE CAL WITH THE ORDER INFORMATION 0 25 0 25 0 25 0 25 0 25 0 25 Feeder Calibration wt sec values assume stroke limiters installed in hoppe Hop1 Continue Stop on Out of Material STOP Hop2 Continue Stop on Out of Material STOP Hop3 Continue Stop on Out of Material STOP Hop4 Continue Stop on Out of Material STOP Hop5 Continue Stop on Out of Material STOP Hop6 Continue Stop on Out of Material STOP Hop Continue Stop on Out of Material STOP Hop8 Continue Stop on Out of Material STOP Hop1 Alarm No Alarm on Out of Material ALARM Hop2 Alarm No Alarm on Out of Material ALARM Hop3 Alarm No Alarm on Out of Material ALARM Percentage Mode 20 0 MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE MUST CALIBRATE Main 25 or
105. pper A calibration weight is provided with all Batch blending systems The calibration weight is stamped with its actual weight on top If this is not available any object with a known weight accurate 0 01 Ibs will suffice The weight should be as close as possible to the maximum batch size you plan to run The weight will be in pounds unless the blender is provided for metric operation In the case of a metric blender display the weight to be used is calibrated in kilograms Given the two weight points on the load cell scale the controller should 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 has a span accuracy of 0 02 The maximum capacity of each load cell is clearly marked on top of the load cell This value will be indicated in kilograms 1 kg 2 2 lbs e The weight scale on a new blender comes pre calibrated but it is recommended to periodically check the calibration to ensure that the reported inventory levels are accurate BLN1 600A Chapter 3 Installation 46 of 116 Verify Weigh Hopper Load Cell Calibration AC SETUP Group CALIBRATION DIRECT SCALE READOUT P Calibration Weight of Stored Calibration Loadcell A Loadcell B Tare Weight god 00 1 oo E EH Cal Bits 0 000 MEUS Current Bits 0 0 0 0 Weight 0 000 0 000 Total Weight 0 600 Total weight minus 0 000 tare We ight
106. r mixer drawer 5 Lower blender slowly 3 2 Mechanical Installation It is the intent of this section to familiarize the reader with the proper site requirements and installation procedures of the Batch 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 The installation procedure should be used as a general guideline for the proper installation steps required to install the Batch blending system 1 Lift blender and position over machine throat or floor stand 2 Setin position and secure by tightening four grade 8 bolts Supplied by customer BLN1 600A Chapter 3 Installation 36 of 116 3 Remove lifting strap 4 If equipped adjust the four leveling bolts on the floor stand blender support rails 5 Mount the material conveying system receivers on the top of the blender supply hoppers 6 Align the weigh hopper on the load cell brackets with air cylinder toward rear of blender 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 e 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 7 Check the slide gate meteri
107. r nnne esee nnne sse nsn ssa n 41 05 aber iem E LS Uu EE 41 Mechahical Setup maca or xvn vr DE arn bU medesime e cn 42 S ke Limiters for Metenin Gate Sisena estesa EORR SEN Rs dus 42 Weieh Hopper InstallatiQDs detecte tripode skeen ba wa sa 43 Pita WG onnectlols emeti tele ee 43 CODIOUEC SCC UD tetes cetacis 44 Plender CalIDEAllOM suits elena letal 46 VARTA 5 Dits ei 49 INDOLIS C DD Sch out els admet times aes daas A 51 Display IP Address and Setting the Time Date eeessseeeeeeeeee 51 Configure the blender for LBS or KGS iiie ve E p RE ve e ves 52 Mixer and Dump Se UIP cease teues tests 22 cocum T 53 CHAPTER 4 OPERATION i scsxxiis sutkrxksYeswEn MKEFESFEKYEYETRa Rus aa v ns 54 NN San oto 54 General Opera ON inire ira ti atu an ex Cad te qi atm eu tudlite Sema uie xau ec ERE 54 QUICK Slat POCO TIC uccide et ente heated at d pU DEAL SU DM ME 55 NEW RO CIDE eternes item talment es ED ES ves un acids 55 Eus tito RECIPE ee ates tastat don IDE de DM ds t LA DEO UM EE D 55 4 2 Operation PfOCedUtes usce oe eb ea EA evi ce ER E EL HE E a Pw RA EB 56 Operator DISD AV m 56 RECIPE ENUY FONNI l Sirini oen t So Bes mei acd best seduta du ETE 61 EZ Recipe Mode Most common in injection molding 62 Percentage Mode Most common in extrusion and blow molding 64
108. rm Log An alarm will sound and a screen will pop up when Auto Inventory Shutdown has been reached E Stop Screen The blender is equipped with an System stop switch that removes the power from all mechanical outputs The System stop Screen appears along with an audible alarm whenever the System stop is activated The operator can not access any screens until System stop is deactivated The Panel View will then put the screen back to the display that the operator was on prior to hitting the System stop The System stop does not provide a category 0 or stop It is recommended that the System stop be moved closer to the power input so as to disconnect all power when the System stop is pushed BLENDING MODE SEQUENCE e Before starting Batch 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 uncovered 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 t
109. rom 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 is set to 1 then the batch will dump normally Normally this is not needed Use Mixer Dump Time to enter the amount of time the mixer knife gate will open to allow material to exit the mixer The mixer will also run to assist during this time Press X to return to the Setup screen Chapter 3 Installation 52 of 116 3 6 Initial Startup The operator can start the blender by touching ion the Recipe Page g The switch will show i when running 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 2 on the Recipe Page This will cause the blender to stop making the current batch immediately If the blender is stopped in this method then the current batch will not be completed properly BLN1 600A Chapter 3 Installation 53 of 116 Chapter 4 Operation 4 1 Start up General Operation The general operation of the Batch 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 batch blending system is powered on the unit will display the recipe screen the rec
110. rs 2 Hopper capacity measured excludes straight wall section and is based on vacuum receiver use Approximate value 3 Measurements describe standard unit without feeder or RAM hoppers 4 See page 75 for important rate information concerning each model s maximum blending rate Note Blender models with 7th and 8th component metering include Allen Bradley 10 inch color touch screen standard Figure 3 Typical Blender Assembly BLNI 600A Chapter 2 Functional Description 15 of 116 2 3 Typical Features and Components Mechanical Features e Exclusive diamond design slide gate metering assemblies meter a large range for free flowing pellet materials Adjustable slide gate stroke limiting restrictors provided for accurate metering of minor ingredients not available on 150 models or removable hopper components e Removable stainless steel weigh hopper and mixing components e Powder coated mild steel material supply hoppers with machined polycarbonate clean out doors and optional material drains stainless steel hoppers on 150 models Precision 0 02 span accurate cantilever load cell weighing system nterlocked safety system shuts off compressed air and electricity if mixer is opened Compressed air hose with nozzle provided as a convenience for clean out Figure 4 Typical Red Lion Touch Screen Display e Your touch screen panel may differ slightly from shown Controller Features LCD touch screen interface d
111. run mode displays that are available on one blender including the recipe book and recipe storage facilities Other items covered in this section are optional printer functions and report generation capabilities of the Batch blending system Topics covered in this section are General Operation Recipe Menu Recipe Book Cleanout Mode Inventory Page Inventory Shutdown Event Recipe Formats Optional Printer Menu All personnel operating the Batch blending system should read this section of the manual before operating the blending system Operator Displays The batch 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 BLN1 600A Chapter 4 Operation 56 of 116 Entering a Recipe Group E Mode ON J 30 0 ei H4 ACS Smej vs ng in new sb 1e e tO Cn nere REQUIREMENTS FOR A VALID RECIPE Regrind hopper cannot be over 100 eee Multiple Virgin hoppers must total 100 Percentage Mode Recipe Total must add to 100 All entries are valid BLN1 600A Chapter 4 Operation 57 of 116 Recipe Book The blender comes standard with a built in recipe book that holds 100 recipes These recipes are stored and synchronized with the displays CompactFlash card You can remove the card and open the recipes csv file using Excel This file has a header row that explains each field You can
112. s have their own separate alarm The alarm will sound but does not stop the blender unless the low levels are configured as Treat as Out of Material AC 4 SETUP Group ALARM SETUP On Out of Material Alarm Silence Delay BO secs 1 From the Setup Menu touch Alarm Setup 2 Making changes to the Retry Alarm settings only affect the recipe after accepted by touching the accept recipe icon and being loaded after the current batch is complete If you want to stop the current batch without waiting for it to complete you must hit the abort icon 3 Press the X key at the bottom to exit this screen BLN1 600A Chapter 3 Installation 50 of 116 Network Setup AC S SETUP IP Oddress 192 158 i m 10 Subnet 255 255 255 Ei The blender IP is the address of this blender on a network The batch blender is factory set up with an IP address of 192 168 0 10 In order to change the values enter the Setup menu press the Network Setup button and change the values accordingly You must touch Send Ethernet Config to Module before the change will take effect After sending it to the module wait 1 minute to test communications Display IP Address and Setting the Time Date The Set Date amp Time feature is located in the Display Config menu of the Setup Screen The time is in Military Time The display has it s own Ethernet port and can be configured by entering in the IP and touching
113. t Mode Empty the blender hoppers Manually operate mixer weigh hopper dump gate and slide gate below mixer View test all inputs outputs on the blender Return to Recipe Page Inventory Page View print accumulated inventories View batch time View maximum capacity View average process rate Return to Recipe Page Maanifv Total Inventorv Setup Page e Touch the ACS icon and enter in user password Chapter 3 Installation Recipe Format Percentage Parts or EZ mode Metering order Batch size Inventory shutdown Batch ready mode Auto start mode Weigh every batch options Change recipe without stopping Report Setup Blender number Auto print option Auto clear option Auto interval option Auto start time Calibration Scale Calibration Direct Scale Readout e Feeder Calibration Mixer amp Dump Setup Mixing time Remix time Dump time Dump delay Dump cycles Mixer dump time Time continuous mixing option Continue stop running on Mivar Failiira Display Config e View software version e Set Time Date e Set Red Lion IP Address e Set Screen Brightness Units e Blender data units Ibs kg e Target v actual data units Ibs kg Alarm Log e View or clear alarm log Alarm Setup Stop Continue when out of material Alarm No Alarm when out of material Alarm Silence delay Accept recipe alarm enable disable Missing ingredient compensation option Low Leve
114. t goes high record the actual weights 2 R hopl displayed target weight L 18 0 target meter weight for batch xxx xxx f39 20 3 R hop2 displayed target weight L18 1 target meter weight for batch xxx xxx 39 21 4 R hop3 displayed target weight L 18 2 target meter weight for batch xxx xxx 39 22 5 R hop4 displayed target weight L18 3 target meter weight for batch xxx xxx f39 23 6 R hop5 displayed target weight L18 4 target meter weight for batch xxx xxx 39 24 7 R hop6 displayed target weight L18 5 target meter weight for batch xxx xxx f39 25 8 R hop7 displayed target vveight L18 6 target meter weight for batch xxx xxx f39 26 9 R hop8 displayed target weight L18 7 target meter weight for batch xxx xxx f39 27 10 R hopl displayed actual vveight L19 0 actual metered weight in batch xxx xxx f39 28 11 R hop2 displayed actual weight L19 1 actual metered weight in batch xxx xxx 39 29 12 R hop3 displayed actual weight L19 2 actual metered weight in batch xxx xxx f39 30 13 R hop4 displayed actual weight L19 3 actual metered weight in batch xxx xxx f39 31 14 R hop5 displayed actual weight L19 4 actual metered weight in batch xxx xxx f39 32 15 R hop6 displayed actual weight L19 5 actual metered weight in batch xxx xxx 39 33 16 R hop7 displayed actual weight L19 6 actual metered weight in batch xxx xxx f39 34 17 R hop8 displayed actual weight L19 7 actual met
115. t option If this was not done at the time of purchase it can be added afterwards by consulting the factory The blender has a programmable IP address and subnet mask that can be programmed from the Panel View that comes with the blender refer to blender manual Ethernet is the standard that we support but AB also supports Device Net DF and DH485 protocol to these PLCs Refer to AB documentation The DF1 port is 19200 baud with no parity and a source ID of 1 This is usually not important since you will be communicating with the Ethernet module instead of directly with the DF1 port Be sure that the DCOMM light is on by depressing the COMMS switch under the PLC front panel After this light is on then you can touch the ACS icon and enter 5413 then select Ethernet Setup program in you IP address click send config to module and then wait about 45 seconds for it to program the new IP address If you cannot ping the module then reboot the blender and try again 45 seconds after booting Below are the items that can be accessed for the blender ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ WRITE GENERAL BLENDER INFO 1 R plc version n23 0 xx x 2 R number of hoppers n9 9 number of hoppers on the blender 3 R maximum blender throughput L15 24 f39 1 maximum rate blender can achieve BLN1 600A Chapter 7 Appendix 109 of 116 4 R average batch time n16 3 average amount of time it takes to finish the ba
116. t you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Figure 53 Typical Troubleshooting Problems and Suggested Corrective Actions Check to make sure that air is hooked up and the regulator gauge reads at precisely 60 PSI Nothing happens when I push Check that the access door to the mixer is shut properly Start Blender 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 cane AR OE elca Check the E stop located on the front of the blender panel Click Unlock and enter in your User Password Interface Locked icon is shown a oven SOT Contact the Service Department Password POWER INTERRUPTION Power was lost during a batch Check your power source unless ALARM you intentionally killed the power during the batch Change out the PLC with your spare and reprogram new unit EC ano Send old PLC back to Manufacturer for repair BLN1 600A Chapter 6 Troubleshooting 80 of 116 Normal after a software upgrade Follow on screen ins
117. tch 5 R average process rate L30 30 f39 2 average rate at which the process is consuming blended material BLENDER STARTING AND STOPPING 1 R blender started b3 0 0 2 RW blender start request b3 0 11 toggle this to start or stop the blender blender will switch it s current status you must also reset this bit after completion 3 RW abort batch request b3 0 8 toggle this to immediately stop the blender even if the batch is incomplete you must also reset this bit after completion BLENDER ALARMS 1 R alarm_number n1 1 74 see below for description 2 R hopl out of material b28 0 0 3 R hop2 out of material b28 0 1 4 R hop3 out of material b28 0 2 5 R hop4 out of material b28 0 3 6 R hop5 out of material b28 0 4 7 R hop6 out of material b28 0 5 8 R hop7 out of material b28 0 6 9 R hop8 out of material b28 0 7 10 R hopper over max alarm b28 0 9 11 R empty weight exceeded b28 0 10 12 R inventory cleared b28 0 11 use this bit to record when an operator cleared the inventory at the blender 13 R power interruption b28 0 15 this alarm engages when the PLC loses power during a batch 14 R hopl low level b29 2 0 this alarm is only available if the hoppers have low level prox switches 15 R hop2 low level b29 2 1 this alarm is only available if the hoppers have low level prox switches 16 R hop3 low level b29 2 2 this alarm is only available if the hoppers have low level prox switches 17 R
118. the knife gate switch located on the side of the back control panel A Slide gates create a pinch point hazard Figure 13 Mixer Slide Gate Switch Positions Slide gate functions are automatically controlled by the blender AUTO controller OPEN Slide gate open all the time CLOSE Slide gate closed all the time Low Level Sensors Detect material supply problems before blender supply hoppers are empty Remote Touch Screen This section describes the optional Remote Touch Screen It is useful in situations when the access to the control panel is difficult or limited This remote control panel may be located up to 50 cable feet away from the blender control panel Note a signal amplifier may be required for long distances Consult factory with actual application The Remote Touch Screen option provides a second operator control The remote interface provides the operator with all the functions of the standard Batch blender control panel The keypad and display are identical to the blender panel Every Batch blender panel includes a remote interface connection and simply plugs into the appropriate connector The remote touch screen is an option and is not included with the standard blender Mezzanine and Floor Stands Supports blenders in mezzanine mount and freestanding applications Figure 14 Typical Floor Stands Surge Hopper Stand amp Gaylord Fill Stand BLN1 600A Chapter 2 Functional Description 30 of 116
119. 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 e The preset part will be divided by the total of all parts with each part representing the calculated weight for ratio control Figure 37 Example Calculations of a 4 component blend in Parts mode Calculated Weight Feeder Tag Preset Part Ratio Control Toa J 1000 I 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 Recipe Setup Metering Order The Batch blender allows the operator to set the ingredient metering order when making a batch In order to access the metering order menu enter the Setup menu and press the Recipe Format button refer to the menu structure on page 39 Once in the Recipe Format menu view Metering Order This display will indicate the current order in which the ingredients are metered A Metering Order of 12345678 means that the blender will feed hopper first and hopper 8 last In order to change the metering order simply press the Metering Order button In the next screen the operator must select a value from to 87654321 and press the green enter key Once the desired metering order is displayed si
120. the selections that are field programmable followed by the procedure for doing so This menu is accessed by pressing the manufacturer s icon when in the Setup Directory Screen menu ADVANCED SETUP Enter the long password 3145348 and press Enter Advanced Setup Menu Metering Test Screen METERING TEST Press to Begin if the blender is stoppped Baile Mid 0001 d Dispensed Weight 0 128 LBs Dispensed Grams 271 800 Dispense Time 0 532 secs This screen is useful when testing the metering performance of each feeder The user can perform test 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 This allows you to open the gate for several feeds using the same time You can then record the Dispensed Grams and plot the standard deviation 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 on a gram scale Refer to the Troubleshooting Section of this manual for additional details BLN1 600A Chapter 7 Appendix 100 of 116 Advanced Weight Options Screen and Feeder Calibration Setup ADVANCED WEIGHT OPTIONS Max Tare Offset RX FEEDER CALIBRATION SETUP Unstable Alarm x Weight Filter LBS
121. ting Every month inspect the auger Hands can become shears blades for any type of entangled or cut if they wear For further information enter the danger zone of see the Maintenance Chapter gears or cutting shears in this manual BLN1 600A Chapter 1 Safety 8 of 116 Mandatory Symbol BLNI 600A Description Explanation Read Operators Manual This equipment must be operated and maintained by properly trained personnel The information contained within this manual must be read and understood prior to operating this equipment Lifting point Heavy load can fall and cause serious injury or possible death Lift equipment at designated points Disconnect before opening Before servicing or maintaining the machine be sure to disconnect the power and or compressed air source to avoid electrical shock and or serious injury Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Chapter 1 Safety 9 of 116 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when insta
122. tion 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 Figure 22 Typical Floor Mount Central Blender Layout BLENDER KNIFE GATE BELOVY MIXER SURGE HOPPER FLOOR STAND TAKE OFF COMPARTMENT 3 3 Electrical Connections The standard Batch blending system is designed to operate on 120 240 1 60 or 110 220 1 50 supply voltage 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 BLN1 600A Chapter 3 Installation 39 of 116 If a step down transformer was provided it should never be used to power anything other than the blender Loading equipment 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
123. tructions 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 Check the power supply Make sure that it has 5 VDC output to the CPU 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 Check batch weight setting in the recipe menu See the setup chapter for more information Check the load cells and weigh hopper mounting for binding etc Check to see that a pellet has not lodged under a load cell 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 cause an overfill condition on the next few cycles Check the load cell
124. ues If you see xxx xxx above this means the data is in fixed decimal and must be scaled when reading or writing A decimal is shown next to each item to represent the format BLN1 600A Chapter 7 Appendix 114 of 116 WRITING RECIPE EXPLANATION To write a recipe you must first write to the temp recipe value locations above After this is complete you should read the accept recipe enabled and the recipe error values If you have a recipe error then you should display the appropriate text If the accept recipe enabled is high then show a button that will then write to accept recipe bit This will load in the recipe You do not need to check the sum of the recipe that they ve entered The blender will do that for you If you chose to write the recipe to the raw recipe locations you run the risk of inadvertently entering the incorrect recipe This is not recommended because it will bypass all the checks that the blender makes before letting you hit accept new recipe Also if you chose to use the raw method then you must add up the totals for your recipe and write that at the exact same time that you write the other raw recipe values You must also right the batch size and recipe entry information or the blender might not make a batch RECORDING THE TARGETS VS ACTUALS FOR EACH BATCH The targets that are read are in lbs or kgs When a batch is complete and dumped the blender will toggle high the print data
125. ull prox for the bin The blender can be configured to perform this feature by entering in an inventory shutdown value under Recipe Format found under Setup see setup section for more details Once a recipe with an inventory shutdown value is started the blender will continue to make batches until the inventory shutdown value has been reached This is checked after the batch dumps so you can end up with a value that is nearly 1 batch greater in weight than the programmed inventory shutdown value Once the inventory shutdown value is reached the blender stops making batches the alarm horn flasher is energized and the page below is shown Touch here after wen we chnreed dre The blender has reached the t Seg inventory shutdown amount and has been stopped Gaylord b Touch here to close hack AC BLN1 600A Chapter 2 Functional Description 29 of 116 2 4 Optional Components The following is a list of options which your blender may have been equipped with Pneumatic Slide Gate below Mixer The Batch 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 function is described below and is determined by the position of
126. ve the weight hopper and press OK After touching OK the controller will display PLEASE WAIT B EA x Ss X9 Next the controller will ask you to hang the calibration weight on the right loadcell bracket loadcell A and press OK 7 The controller will ask you to hang the calibration weight on the left loadcell bracket loadcell B and press OK Does not apply to the BD 150 8 Finally the controller will ask you to replace the weigh hopper in the blender and press OK to complete the calibration 9 The controller will verify that the calibration was done correctly by showing Calibration Successful 10 Press X until you have reached the Recipe screen BLN1 600A Chapter 3 Installation 48 of 116 Feeder Calibration AF amp RAM Components AC SETUP XE AE CALIBRATION FEEDER CALIBRATION x Select Feeder d 100 Blender Must be A 025 Stopped First El 1 00 EE Hopper Weight 0 000 LBS pm Stored Feed Gi 4 FEEDER CALIBRATION SETUP Unstable Alarm imit Batch for Limit Feed Cal Allowed Deviation for 10 Stable F lag Hop fis 10x NOT STABLE YET Hop2 MM 10x NOT STABLE YET Number of Hop3 RE REG NOTSTABLE YET DS lo ao Hop4 10 10 Bc eae aa deviation of a a of TAIC Yt C Trin aa i batch size for target Feeder calibration should be done on all Auger components prior to start up This allows the blender to configure
127. 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 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 BLNI 600A Chapter 2 Functional Description 14 of 116 Figure 2 Equipment Specifications Dimensions and Specifications 150 4 500 900 2500 400 600 Maximum Blending Rate Ibsihr kgs CA Number of Materials to be Blended 2108 Slide Gate Size Majors in mm Slide Gate Size Minors in mm Supply Hopper Capacity Majors cu ft I 2 Supply Hopper Capacity Minors cu ft I 2 1 5 0 Weigh Hopper Capacity cu ft I 0 07 20 0 18 50 0 38 11 0 82 23 1 23 34 2 17 61 Typical Batch Size Ibs kgs 4 1 8 8 3 6 25 11 3 35 15 8 45 20 4 Load Cell Capacity kgs 2 Q 15 kg 2 20 kg Miser Capacity CUTE Weight of Machine approx Ibs kgs A ge 37 5 952 46 5 1181 1 Compressed air loaders CANNOT be used to load 150 blende

ACS Blender CSG User's Manual

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