Gravimetric Slide Gate Auger Batch Blender Red-Lion Display Models: BD, CSG, SGBD Part Number: 882.02148.00 Bulletin Number: BLN1-600A 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.
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.
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 purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid.
Table of Contents CHAPTER 1: SAFETY................................................................ 7 1-1 How to Use This Manual .............................................................................................. 7 Safety Symbols Used in this Manual ..................................................................... 7 1-2 Warnings and Precautions ......................................................................................... 10 1-3 Responsibility ......
Floor Mount (Central Blender) ............................................................................ 39 3-3 Electrical Connections ................................................................................................ 39 3-4 Pneumatic Connections .............................................................................................. 41 3-5 Initial Set-up ............................................................................................................
7-3 7-4 7-5 7-6 Mixer Sub-Assembly ........................................................................................... 87 Hopper Sub-assembly ......................................................................................... 89 Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional) .................. 90 Weigh Hopper Sub-assembly ............................................................................. 92 Slide Gate Sub-assembly ....................
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.
Figure 1: Safety Tags and Warning Labels Hazard Alert Symbol BLN1-600A Description/Explanation Preventative Maintenance Pinch point slide gate. Hands can become entangled or cut if they enter the danger zone of gears or cutting shears. Every month inspect the shears/blades for any type of wear. For further information see the Maintenance Chapter in this manual. High voltage inside enclosure. The electrical enclosure is supplied with 3-phase electrical power.
Mandatory Symbol 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.
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.
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.
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: • NEVER place your hands or any part of your body in any dangerous location. • NEVER operate, service, or adjust the blender without appropriate training and first reading and understanding this manual.
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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for the BD, CSG, and SGBD Series slide gate blenders of various blending rates and specifications. See below for a list of available models.
Figure 2: Equipment Specifications Dimensions and Specifications Maximum Blending Rate, lbs/hr (kgs/hr) (*4) 150 (*1) 500 900 2500 4000 6000 150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725) Number of Materials to be Blended Slide Gate Size - Majors, in. (mm) 2 to 4 2 to 6 2.0 (50) 2.0 (50) 2.5 (63) Slide Gate Size - Minors, in. (mm) 1.5 (38) 1.5 (38) 2.0 (50) 3.0 (7 5) Supply Hopper Capacity - Majors, cu.ft. (l.) (*2) 0.7 (20) 1.4 (40) 3.0 (85) 7.
2-3 Typical Features and Components Mechanical Features • Exclusive diamond design slide gate metering assemblies meter a large range for freeflowing pellet materials • Adjustable slide gate stroke limiting restrictors provided for accurate metering of minor ingredients (not available on 150 models, or removable hopper components) • Removable stainless steel weigh hopper and mixing components • Powder coated mild steel material supply hoppers with machined polycarbonate cleanout doors and optional material
• 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.
Slide Gates Air operated slide gates are provided to meter the majority of pellet ingredients on Slide Gate blenders. • The metering range assumes 1/8” diameter free-flowing plastic pellets weighing approximately 35 lbs./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.
Figure 6: Typical Slide Gate Assembly 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.
Figure 7: Typical Weigh Hopper Assembly 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.
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 The mixer is designed to provide bi-directional mixing action and can be easily taken apart for cleaning. This design is standard on all Slide Gate blenders.
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. 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.
Changing the Language Touch here to bring up Language Selection Page Language Selection Page Touch the Flag of your Country to change the language BLN1-600A Chapter 2: Functional Description 23 of 116
Recipe Page Ingredient Number and Type Touch to change recipe value Cleanout blender when blender is stopped Access to Setup Access to Setup is not secured (see Advanced Settings) Recipe Mode Lock/Unlock interface so no changes can be made Simulator Enabled for Demo Mixer Status Hopper Weight Show Inventory Data Recipe Book Start/Stop blender Abort current batch Touch screen interface is unlocked. To lock touch the lock icon and enter in the password. Touch screen interface is locked.
Entering a Recipe Touch to change recipe value Touch here to Cancel Entry After typing in new value touch here to accept Touch here to Accept the new recipe Touch here to Undo recipe change REQUIREMENTS FOR A VALID RECIPE EZ Mode Percentage Mode Parts Mode BLN1-600A Regrind hopper cannot be over 100%. Multiple Virgin hoppers must total 100%. Recipe Total must add to 100%. All entries are valid.
Recipe Book Touch here to bring up the Recipe Book Touch arrows to increase/decrease recipe number. You can also enter in the recipe number if you know it. Touch here to close the Recipe Book without loading a selected recipe If you’ve modified a recipe the SAVE icon will appear.
Cleanout Mode Touch here if blender is stopped 3 Touch here to Cancel Cleanout mode Touch hopper icon to open/close feeder Touch weigh hopper icon to open/close Touch mixer icon to start/stop Touch knife gate icon to open/close BLN1-600A Chapter 2: Functional Description 27 of 116
Inventory Page Touch here to bring up the Inventory Page Average Batch time in seconds Touch here to close the Inventory Page Max Blender rate with current recipe Material weight that has been weighed and dispensed through the weigh hopper Batches counted in Total Inventory Print Inventory Consumption rate of process Clear Inventory. You will have to enter your password and confirm.
Inventory Shutdown Event The blender has a feature called “inventory shutdown”. This is typically used to fill gaylords without the need of a “full” 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.
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.
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.
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.
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: • 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.
Figure 17: Electrical Disconnect Plug 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 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 19: Electrical Safety Interlock Switch (Located on mixer door) A unique electric safety switch is 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.
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. 3. Lift blender until strap is taut. 4. Remove bolts attaching bottom of blender to shipping skid, bolt located under mixer drawer. 5.
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.
• 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. • Larger blenders need to be braced as part of the installation.
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.
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.
supply wiring to the control panel. Care must be taken to ensure that the supply wiring does not interfere with the low voltage DC wiring. The blender is equipped with a plug that functions as the disconnect device (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.
Mechanical Set-up Stroke Limiters for Metering Gates Stroke limiters are supplied on components 1 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.
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 • 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.
Controller Set-up This section describes the proper setup of the batch blending system control parameters. These parameters are operator changeable; however, these items should only require setup during the initial installation. Only authorized personnel should change them. For security reasons, the menu that is used to access these parameters is password protected. Many of the variables and setup parameters have been preset at the factory and do not need to be changed.
Menu Structure for Batch Blenders Recipe Page—Start Ø Change Recipe Values by touching the number you wish to change Ø Touch “Accept New Recipe” button after you’ve made the desired changes Ø Touch “Undo” button to cancel a recipe change before accepting it Ø Start or stop the blender by touching the “Push to Start or Stop” button Ø Access “Recipe Book ” Page Ø Access “Clean Out” Mode Ø Access “Inventory” Page” Ø Access “Setup” Page Ø Lock/Unlock User Interface User Interface Lock • Lock the user
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.
Verify Weigh Hopper (Load Cell) Calibration Weight for each loadcell Verifying Calibration (Recommended on a periodic basis to ensure accuracy) 1. The blender must be stopped before this can be done. 2. From the Setup Menu touch “Calibration” and then “Direct Scale Readout”. 3. Remove the weigh hopper. 4. Locate the weight display for each of the two load cells. Write down the displayed value. 5.
Weigh Hopper (Load Cell) Calibration (Recommended only if the calibration is out of spec) Enter in the Calibration Weight Current Loadcell Bits Follow Instructions 1. The blender must be stopped before this can be done. 2. From the Setup Menu touch “Calibration” and then “Scale Calibration”. 3. Enter in the scale calibration weight value stamped on the side of the weight. 4. The controller will prompt you to remove the weight hopper and press OK. 5.
Feeder Calibration (AF & RAM Components) Pick a Hopper and Follow instructions Follow Instructions Stored Feed Calibration values Number of batches to allow blender to stabilize before alarm % deviation of last 3 measured feeder calibrations % of batch size for target weight during manual feeder calibration Feeder calibration should be done on all Auger components prior to start-up. This allows the blender to configure the parameters which will best suit the auger size and gearbox ratio of the feeder.
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 switches have their own separate alarm.
Network Setup Enable/Disable Modbus+ communications module Touch here to Program the Ethernet Module with settings Set IP and Subnet Select if Ethernet module is configured by PLC or by a separate server. 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.
Units Configure the blender for LBS or KGS. Mixer and Dump Setup The settings listed below are set at the factory and typically do not require any change. 1. From Setup touch “Mixer and Dump Setup”. 2. Enter a “Mixing Time”. This is the amount of time to run the mixer after a batch is dumped into the mixing chamber. 3. 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. 4.
3-6 Initial Startup The operator can start the blender by touching on the Recipe Page. The switch will show 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 on the Recipe Page. This will cause the blender to stop making the current batch immediately.
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 recipe format should be in “EZ Recipe” mode).
Quick Start Procedure New Recipes 1. 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. • Hopper #3 on some models is equipped with an oversized square gate to assist in the feeding of the regrind material. 3.
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 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.
Entering a Recipe Touch to change recipe value Touch here to Cancel Entry After typing in new value touch here to accept Touch here to Accept the new recipe Touch here to Undo recipe change REQUIREMENTS FOR A VALID RECIPE Regrind hopper cannot be over 100%. Multiple Virgin hoppers must total 100%. Recipe Total must add to 100%. All entries are valid.
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 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.
Cleanout Mode Touch here if blender is stopped 3 Touch here to Cancel Cleanout mode Touch hopper icon to open/close feeder Touch weigh hopper icon to open/close Touch mixer icon to start/stop Touch knife gate icon to open/close BLN1-600A Chapter 4: Operation 59 of 116
Inventory Page Touch here to bring up the Inventory Page Average Batch time in seconds Touch here to close the Inventory Page Max Blender rate with current recipe Material weight that has been weighed and dispensed through the weigh hopper Batches counted in Total Inventory Print Inventory Consumption rate of process Clear Inventory. You will have to enter your password and confirm.
Recipe Entry Formats The Batch 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.
“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, i.e. color. The operator enters in the percentage of regrind and additives, and the virgin percentage is automatically calculated.
Figure 36: Example Calculations of a 5-component blend in “EZ Recipe” mode Virgin (NAT): ??? Additive1 (ADD): 5.00% - of virgin component Regrind (RGD): 30.00% - of total batch Additive2 (ADD): 2.00% - of virgin component Additive3 (ADD): 1.00% - of virgin component Batch Size: 10.00 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.
“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.
This order can be changed while the blender is making a batch without affecting the current running batch. • 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.
Typical Inventory Shutdown User Prompt Operator Screen Touch here after you’ve changed the Gaylord box to restart the weight counter and the blender. This does not clear the inventory shown on the inventory page. Touch here to close this page and go back to the recipe page 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.
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.
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.
To view and change the value of the re-mix timer, refer to the “Mixer and Dump Setup” menu. All current values for Mixing and Remixing Times will be shown on this screen. The re-mix timer default value is factory preset at zero. 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.
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.
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.
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 material. When the controller has determined that the mixer is ready for an additional batch of material, the controller will begin metering material into the weigh hopper assembly.
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.
supply hose to the blender to further ensure that no air pressure is supplied to the blender. 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.
4-3 Shut-down The Slide Gate Gravimetric Blender can be stopped in one of two ways: BLN1-600A 1. 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. 2. If the operator desires to complete the current batch of material, then he can stop the blender using the selector switch icon.
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.
5-2 Preventative Maintenance Our blenders need periodic maintenance to provide long dependable service. Check these elements regularly: • Check functionality of safety circuit daily. • Maintain proper air pressure and drain water from trap assembly on regulator – as required. • Periodically lubricate slide gate rails. Always remove plug and disconnect power before servicing blender. Always read operating manual before operating or servicing blender.
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.
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.
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.
Problem PLC Module Loaded Corrective action Normal after a software upgrade. Follow on-screen instructions. 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.
Problem Recorded Inventory Totals don’t match what I’ve actually used Max Hopper Weight Exceeded Alarm continues to re-occur. Printer did not print Corrective action Check the blender’s scale calibration and verify that the batch hopper is not overfilling. If the hopper is overfilling, adjust your 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.
Problem Corrective action 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.
Problem I can’t calibrate the Scale without an error message. I can’t calibrate the feeder without an error message. Corrective action 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.
Chapter 7: Appendix Annex B Information The following design information is provided for your reference: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
7-1 Drawings and Diagrams Final Assembly Figure 55: Typical Final Assembly Parts List # 1 2 3 4 5 6 7 8 9 10 Description Mixer Assembly 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
Mixer Sub-Assembly BLN1-600A Chapter 7: Appendix 87 of 116
Figure 56: Typical Mixer Assembly Parts List # 1 2 DESCRIPTION FRAME FRAME EXTENSION (NOT SHOWN) 500 872.00093.00 872.00208.00 900 872.00094.00 2500 A0770301 N/A 3 872.00095.00 872.00096.00 A0770300 872.00226.00 872.00097.00 872.00098.00 A0770316 872.01318.00 5 TOP PLATE MOUNTING BRACKET – MIXER MOTOR MIX CHAMBER BACK PLATE 872.00099.00 872.00100.
Hopper Sub-assembly Figure 57: Typical Hopper Assembly Parts List # 1 2 3 4 5 6 7 8 DESCRIPTION 2-COMPONENT HOPPER 3-COMPONENT HOPPER LEXAN DOOR DOOR LATCH 3.5” SIGHT GLASS 4.5” SIGHT GLASS (OPTIONAL) 2” DRAIN W/ MANUAL GATE (NOT SHOWN) (OPTIONAL) 3” DRAIN W/ MANUAL GATE (NOT SHOWN) (OPTIONAL) BRACKET - LOW-LEVEL SENSOR (NOT SHOWN) 500 900 4000 6000 Consult Factory A0770286 A0770076 832.00096.00 N/A N/A 832.00095.
Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional) Figure 58: Typical R.A.M. Hopper Assembly Parts List # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION THROAT CLAMP FEEDER TUBE DRAIN HOUSING DRAIN SLIDE GATE MOTOR MOUNT BRACKET SEAL – AUGER - TEFLON MOTOR - AUGER AUGER HOPPER 2.0 CU.FT. HOPPER 7.0 CU.FT. DOOR LATCH SAFETY INTERLOCK SWITCH BRACKET – SAFETY SWITCH SIGHTGLASS 4.
Hopper Additive Feeder Sub-Assembly (Optional) Figure 59: Typical Additive Feeder Hopper Assembly Parts List # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DESCRIPTION THROAT MOTOR MOUNT BRACKET MOTOR – AUGER THROAT ADAPTER – 2” RISER HOPPER 1.0 CU.FT. HOPPER 2.0 CU.FT.
Weigh Hopper Sub-assembly Figure 60: Typical Weigh Hopper Assembly Parts List # 1 2 3 4 5 DESCRIPTION WEIGH HOPPER AIR CYLINDER CLEVIS – AIR CYLINDER FITTING – AIR TUBING AIR TUBING (NOT SHOWN) BLN1-600A 500 900 872.00103.00 872.00104.00 245.00003.00 2500 A0770312 4000 872.00229.00 A0770248 35460 35449 A0770126 35085K A0770139 207.00021.00 Chapter 7: Appendix 6000 872.00230.
Slide Gate Sub-assembly Figure 61: Typical Slidegate Assembly Parts List # 1 2 3 4 5 6 7 DESCRIPTION HOUSING (DOUBLE DIAMOND) (#1-4) HOUSING (SQUARE / DIAMOND) (#1-4) HOUSING (DOUBLE DIAMOND) (#5-6) GATE – DIAMOND (#1-4) GATE – SQUARE (#1-4) (NOT SHOWN) GATE – DIAMOND (#5-6) GUIDE ROD (#1-4) GUIDE ROD (#5-6) AIR CYLINDER (#1-4) AIR CYLINDER (#5-6) CLEVIS – AIR CYLINDER (#1-4) CLEVIS – AIR CYLINDER (#5-6) FITTINGS – AIR CYLINDER STROKE LIMITER (#1-4) STROKE LIMITER (#5-6) BLN1-600A 500 900 2500 4000
Knife Gate Sub-assembly HD (Optional) Figure 62: Typical Slide Gate (below mixer) Assembly Parts List # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DESCRIPTION BASE FRAME MOLDED THROAT SPACER PLATE FLANGE ADAPTER KNIFE BLADE MOUNTING BRACKET – AIR CYLINDER AIR CYLINDER MOUNTING NUT – AIR CYLINDER CLEVIS – AIR CYLINDER BUSHING 1/4 - 1/8 NPT ELBOW 1/8 NPT SOLENOID 4-WAY 24VDC FITTING – 1/8 NPT X 1/4 TUBE MUFFLER 1/8 NPT FLUSH FITTING – 1/4 NPT X 1/4 TUBE SAFETY SHIELD STROKE LIMITER PIPE (NOT SHOWN) BLN1-
Knife Gate Sub-assembly RD (Optional) Figure 63: Typical Slide Gate (floor stand) Assembly Parts List # 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION HOUSING FRAME GUARD SAFETY COVER ROD GUIDE GATE – SLIDE BLADE AIR CYLINDER CLEVIS – AIR CYLINDER NUT – LOCKING FITTING ELBOW 1/8 NPT X 1/4 TUBE NIPPLE 1/8 NPT SOLENOID 4-WAY 24VDC FITTING STRAIGHT 1/8 NPT X 1/4 TUBE FITTING MUFFLER STONE 1/8 NPT BLN1-600A Chapter 7: Appendix All Models 872.00297.00 872.00298.00 832.00049.00 872.00236.00 245.00016.
Control Panel Layout Figure 64: Typical Allen-Bradley Controller Main Parts List* # 1 2 3 4 5 6 7 8 Description Allen-Bradley PLC MicroLogix 1500 Allen-Bradley PLC Base Unit 24 vdc Power Supply Calex Module – Load Cell Amplifier Alarm Light Red Beacon 24 vdc Alarm Horn 95db 24vdc Motor Contactor Motor Overload – MCP (115v unit) Motor Overload – MCP (230v unit) Power Switch (115v unit) Power Switch (230v unit) 9 10 150 500 A0558252 A0558251 900 2500 891.00024.00 891.00744.00 A0563932 724.00117.00 736.
PORTANT INFORMATION CONCERNING MAX. BLENDING RATE LISTED: • • • • • 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. Recipes with more than 50% regrind will significantly reduce the throughput, and minor ingredient accuracy, of the blender. Consult the factory for achievable rates.
7-3 Spare Parts Kits * Figure 66: Blender Spare Parts Listing Spare Parts Kits BD; CSG; SGBD 150 500 900 2500 4000 6000 “A” Kit - Consumables Load cell assembly Mixer high-level sensor A0574120 # # A0574134 724.00767.00 A0574137 724.00768.00 A0574125 724.00770.00 A0556548 A0574140 724.00771.00 A0574143 724.00772.
7-4 Addendum (Service 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.
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 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 Weight Options Screen and Feeder Calibration Setup 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.
Feed Algorithm Options Screen 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.
Mechanical Options Screen 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.
Feeder and Type Setup 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.
Advanced Alarm Options 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.
Password Setup Use this page to configure all passwords. Diagnostic Data This page is used to monitor target vs. actual data for all feeders.
Factory Default Parameters BLN1-600A Chapter 7: Appendix 107 of 116
BLN1-600A 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.
4 (R) average_batch_time, n16:3 (average amount of time it takes to finish the batch) 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 ba
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) hop1_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
RECIPE INFO (THIS IS WHERE YOU RIGHT THE NEW RECIPE TO) 1 (RW) temp_recipe_entry_mode,n9:11 (0=percentage mode, 1=parts mode, 2=EZ mode) 2 (R) temp_batch_size_recipe_value,L21:53 (xxx.x lbs or kgs) 3 (RW) pv1_hop1_temp_recipe_value,L20:0 (xxx.xx, write your new recipe here) 4 (RW) pv1_hop2_temp_recipe_value,L20:1 (xxx.xx, write your new recipe here) 5 (RW) pv1_hop3_temp_recipe_value,L20:2 (xxx.xx, write your new recipe here) 6 (RW) pv1_hop4_temp_recipe_value,L20:3 (xxx.
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 hop1-hop8 from above, you must manually add this if 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.
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.
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.
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 manual for your convenience.
