www.conairgroup.com USER GUIDE UGB011-0208 TrueBlend ™ Gravimetric Blender Software Version V2.9.
Copyright © 2008 Conair The information contained in these operating instructions, including any translation thereof, is the property of Conair and may not be reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise, nor stored in any retrieval system of any nature for any purpose) without the express written authority of Conair • To every person concerned with commissioning of the devices/systems it is recommended to read thoroughly these operating
Contents TrueBlend™ Contents 1.0 User instructions................................................................................................ 7 1.1 1.2 1.3 1.4 1.5 About this operating manual.................................................................................... 7 Layout of the manual............................................................................................... 8 Meaning of safety information ..............................................................................
TrueBlend™ Contents 4.5.2 Electrical connection .................................................................................. 35 4.5.3 Hopper loader connection (option)............................................................. 36 5.0 Structure and function .....................................................................................37 5.1 Structure of the unit............................................................................................... 37 5.
Contents 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 4 TrueBlend™ Start-up.................................................................................................................. 56 7.7.1 Checking functions in manual mode .......................................................... 56 7.7.2 Calibrating .................................................................................................. 60 7.7.3 Input TrueBlend Model/Name (for service users only!) (Level 3) ...............
TrueBlend™ Contents 7.17 System info ......................................................................................................... 102 7.18 Maintenance ....................................................................................................... 103 7.19 Hopper loaders (Optional)................................................................................... 105 7.19.1 Go to Material loading (conveying) overview screen ............................... 105 7.19.
Contents 9.7 10.0 TrueBlend™ 9.6.5 TrueBlend Weigh Bin Mount Installation and Adjustment models TB45 and TB100..................................................................................... 136 9.6.6 Load Cell Removal and Installation for Trueblend models, TB250, TB500 and TB900............................................... 139 9.6.7 Replacing controller ................................................................................. 143 Cleaning ..................................................
TrueBlend™ User Instructions 1.0 User instructions 1.1 About this operating manual This operating manual is a component of the TrueBlend Gravimetric blender. It contains important instructions on the correct operative and maintenance of the unit. Follow these instructions to avoid dangers, to prevent repair expenses and downtime and to increase the service life of the unit. The manual must be kept for referral with the unit at its place of use.
User Instructions 1.2 TrueBlend™ Layout of the manual This manual is classified into several main parts: • User information, • Safety, • Technical specifications, • Transport and setup, • Structure and function, • Operation, • Maintenance and repair, • Decommissioning and disposal, • Appendix (menu structure).
TrueBlend™ 1.3 User Instructions Meaning of safety information Safety instructions are placed before the work steps. Read the safety instructions carefully before carrying out the subsequent operation. If safety instructions are not followed, serious personal injury - possibly with fatal results - and property and environmental damage may occur! The safety instruction in this operating manual are indicated with a symbol. The symbol contains a signal word indicating how serious the danger is.
User Instructions 1.4 TrueBlend™ Pictograms for safety and information In this operating manual you will find sections of text that a re identified by pictograms. The meaning of the pictograms is described below. Pictogram for general identification of hazards. This pictogram occurs in connection with safety instructions (see 1.3 Meaning of safety information). Pictogram for hand injury. This pictogram occurs in connection with safety instructions (see 1.3 Meaning of safety information).
TrueBlend™ Safety 2.0 Safety 2.1 General This chapter contains basic safety instructions for working with the gravimetric batch blending unit. Observe all the instructions for the operation and maintenance of the unit in this chapter. In addition, observe the warning notices that are placed before the action directions where the operating steps are described. 2.2 Safety Hazards MIX BLADES Mix blades are driven with substantial torque.
Safety TrueBlend™ SLIDE GATE/MIX CHAMBER NEVER use your fingers to move a sticking slide gate under the mix chamber. 2.3 Safety Features SAFETY INTERLOCK SWITCH The ACCESS DOOR is equipped with a safety interlock switch that prevents the mix motor from running and the slide valves from operating. DO NOT defeat this safety switch HOPPER FINGER GUARDS Finger guards are fitted into each hopper compartment. DO NOT reach through these guards.
TrueBlend™ Safety Do not make any changes to the unit. Any changes may adversely affect the safety of the unit. Designated use includes following this operating manual and following the specified maintenance intervals and conditions. Please contact Conair if you have any questions about the designated use of the unit.
Safety 2.5 TrueBlend™ Sources of danger The unit is manufactured to comply with the state of the art in technology and the generally accepted rules of safety engineering. However, operation of the unit may give rise to dangers for life and limb of the operator or third parties or damage to the unit or other property. The unit has four sources of danger, which are shown in the figure below: Fig.
TrueBlend™ Safety The sources of danger and the consequences are shown in more detail below: Danger source Consequences Electrical system Fatal injury by electric shock! High voltages can cause life-threatening currents in the body and electric shock. Î Allow only trained and qualified electrical technicians to work on the electrical system. Î Before any electrical work disconnect the unit from the power supply and lock to prevent unauthorized persons switching it on.
Safety TrueBlend™ Danger source Consequences Pneumatic seal on the discharge slide gate 2 at bottom of mix chamber Danger of injury by moving parts! 2 16 Horizontally moving pneumatic cylinders can cause crushing, impact and shearing injuries and bone fractures. Î Do not reach into the pneumatic discharge slide gate during normal operation and during manual operation.
TrueBlend™ 2.6 Safety Safety devices Safety devices protect your health and your life. Do not operate the unit without effective safety devices. DANGER OF INJURY! WARNING! 2.6.1 The operator runs the risk of injury if the safety devices are not operating correctly. Î Check that the safety devices function correctly after work has finished (see 7.7.1 Testing the mix chamber safety interlock switch). Position of safety devices Electrical System/Power Cabinet Fig.
Safety 2.6.2 TrueBlend™ Safety device Safety function Safety guard Prevents injury by crushing and impact at the pneumatic cylinder of the supply hopper. Safety interlock switch Stops the mixer motor when the main door is opened. EMERGENCY STOP switch Stops all movement of the machine. Padlock Locks the switch to prevent unauthorized persons switching it on. Detachable Material Hopper Procedure Detachable material hopper for TB45 (4 bins) TB100 (2 bins) and TB250R-4 (2 bins) models.
TrueBlend™ 2.7 Safety Warning symbols on the unit The instructional, warning and prohibition signs on the unit are a component of the operating manual. Observe and follow these signs in the same way as with the manual. Keep the signs clean and legible and never remove them, paint over them or stick other signs over them. 2.7.1 Position of warning symbols on the unit Fig.
Safety 2.7.2 TrueBlend™ Meaning of warning symbols on the unit Symbol 2.8 Meaning Explanation Warning of hazardous electrical voltage Only electrical technicians may work on the electrical system. Warning of injury to hands Do not reach into the pneumatic seal on the supply hoppers and the discharge slide gate during operation. Never touch the mixer blades. Information for the operator The operator is responsible for the designated use of the unit. 2.8.
TrueBlend™ 2.9 Safety Information for operating and maintenance personnel Persons who are required to operate and maintain the unit must read and understand the operating manual, particularly the section on safety, before starting work. The following safety instructions are particularly important for avoiding personal injury and property damage: • Observe all safety and danger information on the unit. • Keep all unauthorized people clear of the unit.
T r u e Bl e nd™ Technical Specifications TB45-4 TPBM024-0207 Front view Side view C 1 Top view Position 1 Position 2 ‡Position 4 ‡Position 3 B 3 4 4 A Control Drain chute D Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and simple cleanout. Maximum loader sizes 8 inch loaders 22 30.90 {785} 23.63 {600} 25.78 {655} 8.25 {209.6} 9.25 {235.0} 4.75 {120.6} Mixing chamber access door this side of the interface.
Technical Specifications TrueBlend™ TB100-4 TPBM025-0207 Side view Front view Top view B C Position 2 Position 1 1 4 4 3 A ‡Position 4 ‡Position 3 Control Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and simple cleanout.
Technical Specifications T r u e Bl e nd™ TPBS026/0207 TB250-4 and TB250-6 Front view Side view Top view B C 4 position Position 2 Position 1 1 Position 2 Position 1 3 ‡Position 3 ‡Position 6 4 6 position A ‡Position 4 ‡Position 3 ‡Position 4 ‡Position 5 Control B - Width C - Depth D - Control height E - Control width F - Control depth Weight lbs {kg} Installed Shipping Voltage total amps 115V/1 phase/60 hz 230V/1 phase/50 hz Compressed air requirements Discharge valves Maximum loade
T r u e Bl e nd™ TB250-R-4 Technical Specifications TPBS035-0207 Side view Front view C B Top view 4 position 1 ‡Position 2 Position 1 4 3 A ‡Position 4 ‡Position 3 Control Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and simple cleanout. Maximum loader sizes 15 inch loaders - number of loaders 8 inch loaders- number of loaders - Edition: February 2008 57.50 {1461} 36.50 {926} 38.88 {988} 8.25 {209.6} 9.
Technical Specifications TrueBlend™ TB500-4 and TB500-6 TPBS027-0207 Front view Side view Top view B C 4 position Position 1 1 4 6 position Position 1 Position 2 ‡Position 5 ‡Position 4 Position 2 3 ‡Position 6 ‡Position 3 A ‡Position 3 ‡Position 4 Control D Drain chute Maximum loader sizes 15 inch loaders - number of loaders 8 inch loaders - number of loaders - 26 11 {5000} 1550 {703} 2.7 {76.4} 2.7 {76.4} 4 4 2 - (100/60 mm) 2 - (30 mm) 11 {5000} 1200 {544} 2.7 {76.4} 1.35 {38.
T r u e Bl e nd™ and Technical Specifications TB900-4 TB900-6 TPBS028-0207 Side view Top view Front view B C 4 position Position 1 6 5 Position 2 Position 2 ‡Position 5 ‡Position 4 4 ‡Position 3 ‡Position 6 1 6 position Position 1 A ‡Position 4 ‡Position 3 Control D Drain chute Maximum loader sizes 20 inch loaders - number of loaders 15 inch loaders - number of loaders 8 inch loaders - number of loaders Edition: February 2008 19.8 {9000} 3500 {1588} 4.4 {124.6} 4.4 {124.
Technical Specifications T r u e Bl e nd™ TB1800-5, Side view C 6 Front view B 5 and TB1800-4 TB1800-6 Top view 5 4 1 2 1 4 3 5 2 3 A 4 front front 4 position 5 position Control 1 2 6 D 3 5 NOTE: Side and front view drawings are shown for model TB1800-6. The bin positions change for a TB1800-4 and TB1800-5 models, see the top view.
TrueBlend™ TB2500-4 Technical Specifications TB2500-5 and TB2500-6 TPBS032-0706 Side view Front view C B 6 Top view 1 2 1 4 3 5 2 4 5 5 3 4 front A front 4 position 5 position 1 2 Control 6 D 3 5 4 F E front 6 position 55 {25000} 9000 {4082} 10 {283} 10 {283} 4 4 (6X6) 0 55 {25000} 8000 {3629} 10 {283} 5 {142} 5 3 (6X6) 2 (2X6) 55 {25000} 7000 {3175} 10 {283} 5 {142} 6 2 (6X6) 4 (2X6) 111.5 {2832.1} 72 {1828.0} 72 {1828.0} 8.25 {209.6} 9.25 {235.0} 4.75 {120.6} 111.
Technical Specifications TB3500-5, TPBS033-0706 Side view B 5 and TB3500-6 Top view Front view C 6 TB3500-4 T r u e Bl e nd™ 1 2 1 4 3 5 2 4 5 3 4 A front front 4 position 5 position Control 1 2 6 D 3 5 E F 4 front 5 position 77 {35000} 12000 {5443} 18 {510} 18 {510} 4 4 (6X6) 0 77 {35000} 11000 {4990} 18 {510} 9 {255} 5 3 (6X6) 2 (2X6) 77 {35000} 10000 {4536} 18 {510} 9 {255} 6 2 (6X6) 4 (2X6) 156 {3962} 72 {1828} 72 {1828} 8.25 {209.6} 9.25 {235.0} 4.75 {120.
TrueBlend™ Edition: February 2008 Technical Specifications 31
Technical Specifications 32 TrueBlend™ Edition: February 2008
TrueBlend™ Transport and Setup 4.0 Transport and setup 4.1 Unpacking MATERIAL DAMAGE! CAUTION! 4.2 Forces that are exerted on the load cell from outside when attaching and removing the weigh bin load cell may damage the very sensitive load cell. Î Do not use excessive force on the load cell. Lifting DANGER OF INJURY! WARNING! If the weight is unevenly distributed, the mixing unit may tip and injure people when it is lifted. Î Use only the lifting lug provided to lift the mixing unit. Fig.
Transport and Setup 4.3 TrueBlend™ Setup The unit can be mounted on the processing machine or operated as a centralized mixing station. A frame with reservoir hopper and exhaust box is available if it is used as a centralized mixing station. The frame can be bolted to the floor. Î Make sure that the base is as even as possible. Î Make sure that the switch cabinet and main door are accessible for maintenance work at all times.
TrueBlend™ 4.5 Transport and Setup Making connections 4.5.1 Compressed air connection Î Connect the air hose [1] to the compressed air connection of the unit [2]. The operating pressure must be at least 0.6 MPa (87.0 psi) (6 bar). Î Check the operating pressure with the manometer [3] and if it is different set it to 0.6 MPa. [1] Air hose [2] Compressed air connection [3] Manometer Fig. 6: Connecting compressed air NOTE 4.5.
Transport and Setup 4.5.3 TrueBlend™ Hopper loader connection (option) 4 position Position 1 Position 2 Position 4 Position 3 6 position Position 1 Position 2 Position 3 Position 6 Position 5 Position 4 (250-900 models only) Fig.
TrueBlend™ Structure and Function 5.0 Structure and function 5.1 Structure of the unit [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] Hopper loader Supply hopper a. TB 45 (4 quick access bins) b. TB 100 (2 fixed, 2 quick access bins) Material Vertical dispense valve Weighed batch Level Sensor Manual side gate 3 (Machine mount) Mixing agitator Mixed batch Mixing chamber Load cell Pneumatic cylinder Weigh bin Cover for vertical valve assembly Fig.
Structure and Function 5.2 TrueBlend™ Brief description of the functional units (Item numbers refer to diagram on previous page) The TrueBlend meters and mixes free-flowing plastic granulate (regrind and natural material) and additives. The unit mixes four to six materials, depending on model and configuration. For example, the unit has four material hoppers [2] with mounting flanges for one hopper loader 4 [1] each.
TrueBlend™ 5.3.1 Structure and Function For four component blenders Based on the blender size, the volume of the blender material hopper can vary. On smaller blenders, material hoppers can be removable after unlocking the retainer mechanism used for securing the hopper. This is true with all positions on the TB45 series and color/additive positions (3&4) on the TB100 series. See chart below: 5.3.
Structure and Function TrueBlend™ Pos 1 & 2, Main components Pos 3 & 6, Main or additive components Pos 4 & 5, Additive components 6 position Position 1 Position 2 Position 3 Position 6 Controller location Position 5 Position 4 Front door – (mix chamber) Fig.10; Layout of six component material hoppers All the following six component blenders utilize fixed hopper positions: 5.
TrueBlend™ 5.4.1 Structure and Function Gravimetric mode – General The metering sequence is identical as outlined below with every metering cycle unless Precision Additive™ (PREC) is selected: 1 The regrind is metered by the vertical cone valve as a percentage of the whole batch and fed into the weigh bin. 2 The required quantity of natural material is calculated by the controller and dispensed as the next component. 3 The additive natural (Add N) is metered as percentage of the natural material(s).
Structure and Function TrueBlend™ Your most critical component should be in the bins with the smaller valves. IMPORTANT 4 Changing the target percentages while the blender is running will result in the text changing from “current” to "invalid,” however the current batch will finish. When the percentages add up to 100% the text will again display “current”, the batch number will reset and the blender will continue with the new recipe.
TrueBlend™ 5.4.3 Structure and Function Volumetric mode Volumetric mode is an emergency mode and must only be used if the weighing system fails or in special circumstances. The metering sequence is identical with every metering cycle. 1 First the regrind, then the virgin material is metered through the respective vertical valves by time control and filled into the weigh bin. The load cell does not operate in volumetric mode.
Operation 7.1.1 TrueBlend™ Switch on main switch Î Switch the main switch to "l" (ON). The start screen appears. You are at operating level "0". • Press the icon for the gravimetric batch blending unit (TrueBlend symbol) to open the "TrueBlend Status" screen. • IF your unit has the blender/loader control option, • Press the icon for the hopper loader to open the "Loader Status" screen.
TrueBlend™ 7.2 Operation Menu structure For an overview of the menu structure with the various operating levels (Levels 1-3) see the appendix (see 11.1). 7.3 Navigation The navigation bar is at the bottom of the screen. It contains the following buttons: 7.3.1 Explanation of the navigation buttons OVERVIEW (UNIT HOME) Press this button to open the program start screen. The button is visible but disabled on the "Overview" start screen.
Operation TrueBlend™ Loader settings screen SETTINGS This screen is accessible from the “Loader Status” and all other loader screens. Alarm overview screen ALARM In the event of an alarm message press this button to gain direct access to the alarm overview. The button is visible but disabled on the "Alarm Overview" screen. This screen is accessible from all screens.
TrueBlend™ Operation Help button HELP Press this button to find help on specific functions (online help is not yet implemented). This is an example of a help screen. Disabled button DISABLED Navigation bar functions that are not available are disabled (grayed out).
Operation 7.3.2 TrueBlend™ Explanation of keypad screens Input with keypad When operating the controller you are prompted to input numbers or words. When the relevant input field is pressed a numeric or alphabetical keypad (separate capital and lower case) opens, which you can use to make your inputs. • Confirm your input with . In the alphabetical lowercase keypad you can press to open the numeric keypad.
TrueBlend™ Operation Scroll Press the right/left arrows to scroll forward and back (e.g. with settings for components or recipes). 7.3.3 Explanation of additional screen icons Alarm display In the event of an alarm a warning triangle is displayed at the top right corner. The alarm mode can be set to specify when an alarm is displayed and how the unit behaves (see 7.9.3 Input Alarm mode). Operating level The operating level is shown at top left. There are four operating levels.
Operation TrueBlend™ 7.4 Starting and stopping the blending process 7.4.1 Starting blender process (with set values or factory setting) Î Press the blender icon. The “TrueBlend Status” screen opens. button to start the blending Î Press the process automatically with the last set values or the factory settings. The button signals 7.4.2 . (green bar) Stopping the blending process button to stop the metering Î Press the and mixing process. The button changes to (yellow bar).
TrueBlend™ 7.4.3 Operation Restarting after EMERGENCY STOP Î Switch the main power switch on. Switching on within two minutes: the unit continues the interrupted process. This function is used to keep downtime in the event of a short power interruption as short as possible. The screen that was last open before switching off or power failure is opened. Switching on after more than two minutes: the internal functions are completely reset after switching on. The start screen appears.
Operation 7.5.2 TrueBlend™ Switching off in emergency Î Switch the main switch off. The power supply is interrupted. If the cone valve was open, it is closed. All other machine movement is stopped immediately. The batch is not finished. The main switch can also be locked manually with a lock.
TrueBlend™ 7.6 Operation Logging in/logging out 7.6.1 User levels and password input (for service users only!) (Level 3) The system covers several user levels: • Level : enables access to all guest functions (no password protection) • Level : enables access to all operator functions (password: 3333) • Level : enables access to all setup functions (password: 2222) • Level : enables access to all service functions (password: 1111) After logging out operating level "0" is opened.
Operation 7.6.3 TrueBlend™ Auto logout (for service users only!) (Level 3) The system has an auto logout function. This enables the system to return to operating level "0" after a specified period (default value = 15 min). Î From the “Overview” screen, Press . The "Settings" screen appears. Î Press Setup". NOTE to open "Password If you want to change the password press on the field beside the user level and the calculator will appear allowing you to change the password.
TrueBlend™ 7.6.4 Operation Parameters/Global Reset (for service users only!) (Level 3) The overscreen Î Press the button beside "Parameters". IMPORTANT Please contact Conair service before attempting to make a change to the parameters, number or value. Currently, there are no parameter functions that can be set or changed. The "Control Variable" screen opens. Î Assign a parameter number and a parameter value (no function currently set).
Operation 7.7 TrueBlend™ Start-up Please remove the protective film on the touchscreen control for optimum performance IMPORTANT 7.7.1 Checking functions in manual mode All mechanical parts can be manually actuated with the "Manual Mode" function. If a vertical valve or the mix discharge is opened in manual mode, they are closed automatically by switching the main power switch to OFF or if the power fails.
TrueBlend™ Operation If the unit is running or is being calibrated, it is locked to prevent testing of the manual operation. NOTE Testing alarm beacon button to Î Press and hold the check that the alarm beacon and horn operates. These devices are located on the door of the electrical power box. Checking material hoppers The icons that display the status of the hoppers are at the top of the screen. Î Press the buttons in sequence to check that the various material hoppers valves can be opened and closed.
Operation TrueBlend™ Checking weigh bins, mixers and discharge slide gates Press the buttons beside the unit icon to test the function of the weigh and mix chamber components. Î Press the first button to open and close the weigh bin. or Î Press the middle button to switch the mixer on and off. or Î Press the bottom button to open and close the optional discharge slide gate. 5 or (Flow control valve) Note: Only functions when a pneumatic discharge slide gate is installed.
TrueBlend™ Operation Î To the right of the mixer icon press the middle or . The mixing blades must rotate. Î Open the safety door. The mixing blades must stop. Î Close the safety door. The mixing blades should rotate again. This screen mask will only be closed when all actions have been completed. When you open the door, the mask will appear, indicating an alarm condition.
Operation 7.7.2 TrueBlend™ Calibrating NOTE Conair recommends performing a manual calibration at start-up or material change with a dramatic change in the bulk density of the material being blended. This allows the blender to reach its optimal working point more quickly. 7.7.2.1 Calibrating load cell(s): Calibrating scales - zero calibration The scales are calibrated at the factory. The zero calibration is made to set the scales to "0". During shipment and/or operation minor deviations may occur, e.g.
TrueBlend™ Operation Zero calibration Î Press . "0" is displayed for "Actual Weight". Full calibration (for service users only!) (Level 3) to open the "Full CaliÎ Press bration" screen. Before the "Full Calibration" screen appears, you will be reminded that a full calibration cannot be interrupted: Î Press "Continue" if you want to proceed with the full calibration. or Î Press "Abort" to stop the full calibration. Î Make sure that the weigh bin is empty of material. Î Press “Enter” to confirm.
Operation TrueBlend™ Model Calibration Weight TB045 750 g TB100 1,250 g TB250 3,000 g TB500 6,000 g TB900 10,000 g TB1800 22,000 g TB2500 30,000 g TB3500 50,000 g Î If you wish to change the reference weight, press the number input field and enter the desired weight. . Î Confirm the value with Î Place the reference weight in the weigh . bin and confirm with The current weight is compensated and displayed. The full calibration is complete. Î Confirm with 62 .
TrueBlend™ 7.7.2.2 NOTE Operation Calibrating material throughput The material throughput calibration is automatically run on startup and is selfoptimizing during production. The respective dispensing valve(s) are run with reduced batch weight(s) at startup. The optimum working point is set after several batches. A high mixing precision is quickly reached with a small quantity of material. Finally it is switched to the preset batch weight.
Operation TrueBlend™ "1" indicates the material hopper number. You can scroll forward and back with the arrows. Î Press for material hopper "1". Î Press bin. again to empty the weigh Î Run the process for all components that require calibration. Important: The screen cannot be closed until the procedure is complete. For input of the material percentages, see section 7.9.1 Input of material percentages.
TrueBlend™ 7.7.3 Operation Input TrueBlend Model/Name (for service users only!) (Level 3) Î In the "Overview" screen press the TrueBlend icon. The "TrueBlend Status" screen opens. Î Press . The "Settings" screen appears. Î Press to open the "TrueBlend Model/Name" screen. The "TrueBlend Model/Name" screen appears. Î Select the appropriate TrueBlend model in the dropdown menu (Model 45/100/250/500/900/1800/2500/3500).
Operation 7.7.4 TrueBlend™ Input TrueBlend name Î In the "Overview" screen press the TrueBlend icon. The "TrueBlend Status" screen opens. Î Press . The "Settings" screen appears. Î Press to open the "TrueBlend Model/Name" screen. The "TrueBlend Model/Name" screen appears. Î Assign a name to the unit with alphanumeric keypad to give it a unique identification. Î Confirm with . Explanations of the “minimum retry limit (%)” and “the maximum limit batchweight (%).
TrueBlend™ Operation The batch size limit multiplier controls the maximum batch dispensed, regardless of the condition of the (too much material) alarm button. All blender weigh bins have some excess volume capacity to accommodate variations in material bulk density. This setting uses that excess capacity to improve accuracy. NOTE If running high percentages of light density material (regrind) you should reduce the maximum batch weight setting for this particular model. (See section 7.10.
Operation TrueBlend™ Î Next enter the target weight in the next panel position. The units will be either “lbs” or “kg”. If you need to change from one to the other, please refer to section 7.15 System Setup. Î To start the blender operating, return to the Blender Status screen and press the “On/Off” button. The blender will then begin to weigh the target value. You can return to the Batch Mode screen and monitor process as this is being done.
TrueBlend™ Operation NOTE When the target value has been reached, a screen mask will appear indicating “Target weight of the dispense has been reached”. There is an acknowledge button “OK” to remove the message. NOTE Reaching the preset target weight will also stop the blender operation. To begin another Batch after resetting, return to the Blender Status screen and press the On/Off button.
Operation 7.7.6 TrueBlend™ Advanced Operation Settings (Password level 3 only) Advanced Operation Settings are accessed through the Operating Times (Oper. Times) tab from the blender settings screen. Extrusion process (100%) The parameters that are accessible through these menus are available for advanced users, unusual operating conditions, or setup of the control for blender retrofit applications. It should not be necessary for these parameters to be changed in the majority of cases.
TrueBlend™ Operation The settling time is the time after a component dispensed into the weigh bin, while multiple weight reading are taken. (This time allows the material to settle and the load cells to recover from the dumping process before the final weight reading is taken.) The time should be entered in milliseconds For example, in the above screen shot 2000 milliseconds is entered which equals 2.0 seconds. For most Trueblend applications the default time of 2000 milliseconds should be acceptable.
Operation TrueBlend™ Flow Control Valve time – The flow valve time is the time that the material valve under the mixing chamber is open to allow the material to exit the mixing chamber. (When this option is included) C. Dosing Rates This screen displays the last dosing time. This value can be useful for optimizing blender valve sizing. NOTE The Dosing rates are the flow rates in gm/sec of each component in the mix. This is the same value as is displayed on the individual component screens.
TrueBlend™ Operation 7.7.7 Natural Blend button – The Natural Blend button, when selected, ensures that the blender will only run if all components add up to 100%. A warning hand will be displayed above the ON/OFF button to prevent starting. If the percentages are changed while the blender is running, a warning message will be displayed and the blender will stop the current process.
Operation 7.8 7.8.1 TrueBlend™ Blending process Assigning components – factory default setting The components are assigned at the factory as follows: Component 1: regrind Component 2: natural material Component 3: additive/natural (color) Component 4: additive/natural (color) Component 5: additive/natural (color) Component 6: additive/natural (color) The assignment of the components can also be changed (see 7.9 Component setup).
TrueBlend™ Operation 6 position Position 1 Position 2 Position 3 Position 6 Controller location Position 5 Position 4 Front door – mix chamber Fig.12: Layout of the material hoppers – six position models (only available on TB250, TB500, TB900, TB1800, TB2500, and TB3500) Position 1 Position 2 Position 1 Position 2 Position 6 Position 3 Position 5 Position 4 a. Five Position Position 3 Position 5 Position 4 b. Six Position Fig.
Operation 7.8.
TrueBlend™ 7.8.3 Operation Typical dispense cycle based (7.8.2) settings 1st Step: regrind is metered regrind 20% of total weight = 200 g 2nd Step: Natural material is calculated as 100% of the balance of batch = 686 g (automatically calculated/metered) 3rd Step: additive natural is metered (Color) 2% of N = 13.7 g (automatically calculated/metered) 4th Step: additive batch is metered 10% of total weight = 100 g (automatically calculated/metered) The controller must be set to match this sequence.
Operation TrueBlend™ If too much or too little was metered in a batch, this is compensated accordingly The metering process is self-optimizing on the next batch. The regrind is metered first and deducted from the total batch weight. If there is more than one virgin material, the percentages are interpreted as ratios of the virgin materials and dispensed next.
TrueBlend™ 7.9.1 Operation Input of material percentages Î Input the percentage for the material component by pressing the input field beside "Percent %". Î Input the value with the numeric keypad. Note: If using multiple naturals, they must equal 100%. Î Confirm the value with . The metering rate in g/s is automatically learned by the system, but by completing a manual calibration the blender hones in on the rate with greater precision. 7.9.2 Input of Material type Î After "Mat.
Operation 7.9.3 TrueBlend™ Input Alarm mode Every material component can be assigned a specific alarm mode. The alarm mode shows the alarm response to overmetering or undermetering. The "Warn" mode is set for regrind and “stop” for natural and additives at the factory: Î Press the down arrow for the selection box and select the desired alarm mode. • ------: No alarm message, unit continues to run without message. • Warn.: Alarm message is displayed, but unit continues to run.
TrueBlend™ Operation 7.10 TrueBlend Setup Operating mode, batch weight, mixing time and interval time can be set in TrueBlend Setup. Î Press the TrueBlend body icon (green column) in the center of the "TrueBlend Status" screen. Î The TrueBlend setup will come up. 7.10.1 Setting Operating mode The operating mode specifies whether the unit will operate gravimetrically, volumetrically or in mixed operating mode (see 5.3.1 Operating modes). Î Press the dropdown menu and select the operating mode. • grav.
Operation 7.10.2 TrueBlend™ Setting Weigh Bin Batch Weight Materials with a lower bulk densities (ca. <35 lb/cu ft) may not fit in the weigh bin and granulate may overflow. The batch weight must be reduced in this case. The factory setting is 900 g for the TB100 model or 400 g for the TB045 model, (see chart below).
TrueBlend™ 7.10.3 Operation Setting Mixing time The mixing time shows how long a batch is mixed after discharge from the mixer. The factory setting is 10 to 15 seconds, depending on model. Î Press the input field beside "Mix. time" and input the desired duration in seconds with the keypad. Î Confirm the value with 7.10.4 .
Operation TrueBlend™ 7.11 Working with recipes Recipes are used so constant and recurring production processes can simply be called up instead of being input again and again. The controller can store up to 50 recipes. The recipe must be called before recipe data can be changed, i.e. it must be active. NOTE 7.11.1 Calling recipe status Î Press "Recipe" in the "TrueBlend Status" screen to view the recipe status. Î The recipe screen will appear 7.11.
TrueBlend™ 7.11.3 Operation Save a new recipe Î Press to assign a recipe name and to save the recipe. 7.11.4 Naming a recipe Î Use the scroll arrows to select a storage location for the recipe or input a storage location number directly. Î Assign a recipe name with the keypad. A recipe name has a maximum of eight characters (alpha-numeric). Î Confirm the value with Î Press Edition: February 2008 . to save the recipe.
Operation TrueBlend™ The formula for all components is displayed below in the component view. When it is saved the current data are transferred to the preselected recipe name. Existing recipes can also be overwritten with this method. Saving is only possible if a recipe name has been assigned. Otherwise a warning is displayed and the recipe is not saved. NOTE Error message Î Press on the input field and assign a recipe name. to save the recipe. Î Press 7.11.5 Deleting a recipe Î Press 86 .
TrueBlend™ Operation Î Select the recipe that you want to delete with the scroll arrows or by direct input. Î Press . The recipe is deleted from the memory. 7.11.6 Load/view a recipe Î Press . Î Select the recipe that you want to load with the scroll arrows or by direct input. Î Press . The recipe is loaded and the formula for all components can be viewed.
Operation TrueBlend™ 7.12 Changing material in a blender component (also valid for all other components) 7.12.1 Detachable Material Hopper Procedure Detachable material hopper for TB45 (4 bins) and TB100 (2 bins) models, and TB250R (2 bins). NOTE All detachable material hoppers on the above referenced models are held in place with a captive retainer (screw) held in the hopper support frame.
TrueBlend™ 7.12.2 Operation Manual cleaning: Î Turn the power off with the main disconnect switch on the power cabinet Î Disconnect compressed air Î Open front access door and remove the weigh bin Î Position some type of deflector (cardboard tray) to divert material from collecting in the mix chamber to an outside drum or bucket. Also available is the Conair Drain Chute Accessory. This allows the discharge valves to be operated in the manual mode.
Operation TrueBlend™ Î Open the “quick-release” locks of the mixing chamber end cover and remove it. DANGER OF INJURY! WARNING! After extended operation the edges of the mixing blades can be knife-sharp and may cause injuries by cutting. Î Wear gloves when touching or cleaning the stationary mixer. Cleaning the mixer Î Once the material compartment has been cleaned, remove the deflector Î You will now proceed to clean the mixing chamber and shut off valve at the bottom of the chamber.
TrueBlend™ 7.12.3 Operation Clean-out with optional drain chute with safety interlock Î Open front access door to the mix chamber. Î Remove the weigh bin. Î Position the optional drain chute to redirect material from collecting in the mix chamber to an outside drum or bucket. Be sure to engage safety switch of drain chute into compartment receptacle.
Operation TrueBlend™ Î In the "Overview" screen press the TrueBlend icon. The "TrueBlend Status" screen opens. Î Open the "Settings" screen with Î Press . to switch to “manual mode”. Î Press on the appropriate material hopper icon to open the respective vertical valve. Removing material The dispense valve unit is opened and the material runs out of the material hopper through the optional deflector to the collection receptacle.
TrueBlend™ Operation 7.13 Checking total throughput You can display the total throughput of all components from the status screen. Î Press the “Totals” icon the total weight view. to open The total weight and the batches run are displayed in the center above the TrueBlend body icon (orange column). Î Press to advance to advance to the screen reset totals. Reset All displayed throughputs are listed in the Global Reset. The actual throughput values are in the bottom line.
Operation TrueBlend™ 7.14 Creating reports 7.14.1 Reports for batches, shifts, recipes and scales Î In the "Overview" screen press the TrueBlend icon. The "TrueBlend Status" screen opens. Î In the "Overview" screen press the "Settings" screen. Î Press to open the “Report” selections. • Shift report: Records individual ingredient and total material usage during defined interval. Î Input start time and interval time.
TrueBlend™ 7.14.2 Operation Report generator – TrueBlend Reports The messages from the TrueBlend controller are sent through the message capture and report program “TB_Reports” to a computer. Data can be outputted either through the V 24 serial interface (RS232) or the network port (cable connection to the appropriate computer is required). The serial interface V24 (RS232 can be enabled from the “Overview/Settings” menu The TB_Report Software Package is available from Conair. Contact Conair Sales.
Operation TrueBlend™ Main program window 7.14.3 Operation Converting data Î Select "File/Export data" to open the selection dialog and select the message files that you want to convert. Î Select "Open" to start the export and save the file in csv format. Maintaining files Î Select "File/File service" to open the maintenance window. Î Highlight the position you want to edit and carry out the corresponding action with the icons.
TrueBlend™ Operation Creating reports The "Reports" menu item enables the data of the various message types to be collected. Î Select the desired message type in the menu. Î Input the time range and the Unit No. in the filter dialog. Î Click "OK" to create the report and display it on the screen. or Î Click "Cancel" to stop the report creation. Making settings The program settings for the directories used, the serial port (ComPort), language and printer can be selected in the settings menu.
Operation TrueBlend™ Printer Î Select the printer. Changes of language and printer remain in effect until the program is closed or until the next change. They do not change system settings. Conair UDP Refers to network settings that do not currently exist. Printing online Settings for direct output of messages on screen and/or printer can be made with this function. Î Select "Settings/Print online". Î Select the checkbox for the desired actions and accept them with "Apply" or "Save".
TrueBlend™ Operation If both print modes are used simultaneously print errors may occur in some circumstances. NOTE The status of the online checkboxes is shown in the status line: A displayed letter represents the "Enabled" function. M = Material data B = Batch data W = Scale data R = Recipes A Alarms =
= Print online on printer (in red) Version Î Select the "Info" menu. The current version and the build data are displayed.
Operation TrueBlend™ 7.15 System setup Different settings can be made in the system, such as station name, operating language, date and time settings and units. Setting station name Î Input a station name with the alphanumeric keypad. Setting operating language The operating language can be changed for the entire controller. English (factory setting), Spanish, French and German are available. Î Select the desired language in the selection menu.
TrueBlend™ Operation 7.16 Panel setup Screen settings can be made here. Contrast Î Set the contrast (brightness) of the touch panel (10-100; default 100). Shutoff Î Set the time after which the touch panel will change to sleep mode (10600 seconds; default 180). Contrast shutoff Î Set the contrast (brightness) for sleep mode (10-20; default 10).
Operation TrueBlend™ Module number (for service users only!) (Level 3) Î Input the module number of the controller (default 249). It must always match the last octet of the IP address. After changing the IP address the module is always automatically changed to match the IP address. If it is changed later, the controller must also be switched off and on again. Subnet mask (for service users only!) (Level 3) Displays the current subnet mask of the controller (all models). 7.
TrueBlend™ Operation 7.18 Maintenance In the "Overview" screen Î Press . The "Settings" screen appears. Î Press menu. to open the maintenance The "Maintenance" screen appears. • Total batches: counts the total batches that the TrueBlend has run since first started. • Total convey cycles (material loading option only): counts the total conveying cycles that the hopper loader has run since the first startup. • Batches since maintenance: counts the total batches since the last maintenance.
Operation TrueBlend™ Maintenance prompt The maintenance prompt appears every three months. It indicates that it is time to service the unit. Î Press "OK" to confirm and to close the message window and carry out the maintenance work as required (see chapter 9 Maintenance and repair.). Î Press "Reset" to confirm that maintenance has been carried out.
TrueBlend™ Operation 7.19 Hopper loaders (Optional) 7.19.1 Go to Material loading (conveying) overview screen Î Press the hopper loader icon to open the "Loader Status" screen. The "Loader Status" screen opens. 7.19.2 Switching on hopper loaders buttons on the "Loader Î Press the Status" screen to switch on the hopper loaders you will be using. The status of the hopper loaders is displayed in the hopper loader view. 1. Status: Material required The yellow dot indicates the status "Material required".
Operation TrueBlend™ 2. Status: Material conveying The arrow to the right indicates the status "Material conveying". The vacuum valve is actuated and material is conveyed. 3. Status: Material discharge The arrow point down indicates the status "Material discharging". The vacuum valve is closed. 4. Status: Alarm The flashing triangle indicates a material shortage. The status of the hopper loader is displayed in the background (see also Section 8 Alarm message and trouble shooting).
TrueBlend™ 7.19.3 Operation Changes to Loader Screen Î Press a hopper loader icon in the "Loader status" screen to open this screen. Î Enter the load time and the dump time. The load time can only be changed if the hopper loader is switched off or is in the "Material discharging" status. The minimum load time and the minimum dump time is 2 seconds. The maximum load time and the maximum dump time is 180 seconds. The status of the hopper loader is also shown on the right (display: yellow dot).
Operation 7.19.5 TrueBlend™ Settings Settings Î In the loader “status” and “setup” screens press to open the settings screen to configure the hopper loaders and conveying. Setting type of hopper loader Î Press "Hopper Loader" on the "Settings" screen. Î Input the name and type volume in cubic feet of hopper loader. The appropriate loading and discharge times are preset depending on the type selection. (They can be changed at any time). Type (volume) 0.15 0.50 1.00 1.80 3.
TrueBlend™ Operation connected using an ethernet switch and straight through ethernet cables. See your computer technical help for assistance on setting up a network like this. When blenders are connected together, the last three digits of the ethernet IP address (Home > Settings > Panel setup > IP address) must be unique for each blender.
Operation TrueBlend™ Î To set this system up, enter the loader configuration screen on blender 2. Any loader on blender 2 that will be using the blower on blender 1 should have it’s WCN value changed to the last three digits (octet) of blender 1 as shown. In this example the WCN is changed from 240 to 249. The LCO value refers to the type of device (19=loading, 18=blower) and should never be changed except under direction of Conair service or engineering personnel.
TrueBlend™ Operation In this example, when a loader on blender 2 has a demand, it will send it’s request to the waiting list on blender 1. The loader is put into the queue of blender 1’s waiting list, and when the blower is available and the loader is the next in the list, the loader and blower will be operated to convey the material. Example 2 Suppose that you wish to add a second blower to the above system to use as a spare blower while doing maintenance on the blower connected to blender 1.
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Alarm Messages and Troubleshooting TrueBlend™ 8.0 Alarm messages and troubleshooting 8.1 Signaling alarm message • The alarm beacon flashes. • The alarm message is displayed in the top right corner of the screen as a warning triangle. • The alarm message is displayed as text when navigation bar. NOTE is pressed in the If a dosing unit does not reach the set weight, production does not continue. The metering attempt is repeated several times (number of attempts can be set).
Alarm Messages and Troubleshooting 8.3 TrueBlend™ Deciphering Alarm Messages In front of some alarm messages you may see these designators: C1, C2, C3, C4, C5, C6, along with alarm text. C stands for component and 1,2,3,4,5, and 6 refer to the bin that is causing the alarm. It is important to look at the alarm text and check to see if there is a problem with the component bin number listed. 8.
Alarm Messages and Troubleshooting TrueBlend™ Alarm Message Possible Cause Solution • Component x not enough material (in the example, component #3) • Make sure the material hopper is full or has an adequate material supply. • Component x too much material • Make sure the material dosing rate is correct. If the rate is out of range perform a material calibration. See section 7.7.2.
Alarm Messages and Troubleshooting Alarm Message TrueBlend™ Possible Cause Solution • Tare wrong - The range that can normally be compensated is -50 to 100 g. If the tare value is outside this range it will alarm When the unit starts a new batch check the operation of the weigh bin. OK: Batch is stopped after confirmation and unit is stopped. • Make sure the bin is empty. • Perform a zero calibration. • Make sure the material sensor is adjusted correctly (see Section 9.6). Alarm message is sent.
TrueBlend™ Alarm Messages and Troubleshooting Alarm message "Door open" Meaning of alarm • While running the safety door must be closed. The door was opened while in operation. Correction Î Close safety door. • Mixer motor remains stopped; cycle is stopped. • Safety interlock switch is triggered. • Door is not open but message still appears. Î Check wiring connection to safety switch. Alarm message "Motor fault" Meaning of alarm • Motor protection of the fan motor has tripped.
Alarm Messages and Troubleshooting TrueBlend™ Alarm message No slave or Slave disconnected Meaning of alarm During operation the CAN connection between control console and control board has been interrupted. Communication problem Correction Î Check connections. Î Check the touch screen controller connection Î Check the I/O board connection. If the connections are ok, replace either the I/O board or controller.
TrueBlend™ 8.6 Alarm Messages and Troubleshooting Diagnostic Overview Screens (for service users only!) (Level 3) Access the “Settings” screen from the Blender “Overview” screen. This screen gives more detail to the individual material dispenses making up a particular batch, both target and actual percentages, as well as, the running cumulative weight. This screen shows the information used by the blender for each batch. Six materials are listed regardless how many hoppers the blender has.
Alarm Messages and Troubleshooting TrueBlend™ The bottom line, from left to right, shows an icon when “ON” for the weigh bin valve, the level sensor logic, the mixer, and the flow control valve. The level sensor logic is based on the level sensor and a timer sequence. The next field with the green outline shows the current weigh bin weight. The next button allows the blender to be started or stopped from this remote screen.
TrueBlend™ Maintenance and Repair 9.0 Maintenance and repair This chapter contains detailed maintenance and repair instructions and information on regular inspections. 9.1 9.1.1 Safety Qualifications of personnel DANGER OF INJURY! WARNING! 9.1.2 Maintenance and repairs carried out by insufficiently qualified personnel will result in incalculable risks with negative consequences for people, the machine and the environment.
Maintenance and Repair 9.2 TrueBlend™ Before starting work Before starting work, the following conditions must be met. 9.2.1 Switch off unit/disconnect from compressed air supply DANGER OF INJURY! WARNING! Rotating unit components can catch body parts and pull them in and cause life-threatening crushing, shearing and bone fracture injuries. Î Set the unit main switch to "0" before starting maintenance and repair work. Î Secure the unit to prevent unauthorized restart. 9.3 9.3.
TrueBlend™ 9.4 Maintenance and Repair Mixing chamber instructions To Remove Mixing Chamber: 1 Turn all 1/4-turn fasteners on front panel counter-clockwise until they release. 2 Remove front panel. Some models require lifting the panel to clear 2 screws at bottom. 3 Remove mixing agitator by pulling straight out. You may have to rotate the shaft as you remove it in order to clear the front bin wall. 4 Lift front of mixing chamber to align the locking pins with the release slots.
Maintenance and Repair 9.5 TrueBlend™ Maintenance work Î Monthly maintenance work Drain water separator Î Loosen the knurled screw [2] on the bottom of the water separator [1] and drain the water. [1] Water separator [2] Knurled screw Fig. 14: Draining water separator Visual check Î Check that all screws, attachments and wiring connections are firmly attached.
TrueBlend™ 9.5.1 Maintenance and Repair Annual maintenance work The battery must be replaced during operation. NOTE If it is replaced with the power off, battery-buffered data such as date and time will need to be reset. Replacing controller battery Î Unscrew the four screws [1] on the touch panel case. Î Remove the back cover [2]. The 3 Volt lithium cell is positioned on the right side (viewed from the back). Î Pull the tab [3] to remove the battery [3].
Maintenance and Repair TrueBlend™ Î Make sure the new battery is correctly aligned (see symbol on the battery socket). [1] Mounting screws [2] Cover [3] Lithium battery with tab Fig. 16: Replacing controller battery Î Replace the cover. Î Fasten the cover with the four screws.
TrueBlend™ 9.6 9.6.1 Maintenance and Repair Repair work Calibrate/adjust a sensor with no material present IMPORTANT This style material sensor used prior to September 2007. Refer to section 9.6.2 for instructions on calibrating/adjusting the sensor on units built after September 2007. The level sensor switches when material passes in front of the active area. The level sensor adjustment depends on the type of material and must be adjusted accordingly.
Maintenance and Repair TrueBlend™ Do not hold longer than 5 seconds. Holding 10 seconds locks the sensor. IMPORTANT Î Once unit is installed hold a finger over the sensing part of the sensor and make sure that the LED changes state from green to red – this indicates that the unit is working properly. Î To make sure that the unit is adjusted correctly and not too sensitive, close the door and manually run the mixer.
TrueBlend™ Maintenance and Repair 9.6.1.1 Calibrate/adjust a sensor with material present The green LED flashes slowly (approx. 1 Hz). 1 Press the button and keep it pressed (5...10s). After approx. 5s it flashes faster (approx 2 Hz) (=unit is in the programming mode). The yellow and green LED’s are lit 2 Now release the button. (=unit is set and is in the operating mode). For most applications setting the sensor with the vessel empty is sufficient.
Maintenance and Repair TrueBlend™ 9.6.1.2 Unlocking a sensor 1 Press for at least 10s. 2 Press for at least 10s. IMPORTANT At first the green LED flashes slowly, then faster, After 10s it goes out. The unit is locked. After 10s all LED’s go out for a short time. The unit is unlocked and the LED’s indicate the current operating status. Empty or full adjustments can not be made if the sensor is locked. These instructions are included in case you have inadvertently locked a sensor.
TrueBlend™ NOTE Maintenance and Repair Under a strong static charge the sensor can also be screwed 2-3 mm further into the mixing chamber. This will wipe the material from the probe during mixing. Do not place the probe too close to the mixing blades. This may destroy it! 9.6.2 Calibrate/adjust a sensor with no material present – (This style material sensor used in units built after September 2007.
Maintenance and Repair 5 6 TrueBlend™ Once the sensor is installed and adjusted hold a finger over the front of the sensor and make sure that the yellow LED ring illuminates to indicate that the sensor is functioning properly. Once completetly adjusted, operate the mixer manually to ensure that the yellow LED ring does not light when the mixer blade passes the face of the sensor. If this does occur, make sure the sensor is inserted flush with the rear plate of the mixing chamber.
TrueBlend™ Maintenance and Repair Assemble in reverse order. Note the stroke when installing, otherwise the desired throughput may not be reached. NOTE [1] Hoses [2] Nut [3] Hopper Lid [4] Cylinder cover Fig. 18: Pneumatic cylinder IMPORTANT WARNING! 9.6.4 When disassembling cylinder/valve assemble, measure length of complete assemble (Dim A) and record. This assemble length must be maintained. When reassembling adjust original length to this value. Loc-tite™ all fittings when doing reassemble.
Maintenance and Repair TrueBlend™ MATERIAL DAMAGE! CAUTION! Forces and torque that are exerted on the load cell when installing and removing it may damage the very sensitive load cell. Î Make that no force or torque is applied to the load cell. Removal Î Remove the weigh bin Î See figure 19 below for item numbers. Î The load cells are very sensitive and must be handled with care. Make sure that when the load cell is being removed or installed that there is no torque affects applied to the load cell.
TrueBlend™ Maintenance and Repair [1] Bracket for weigh bin [2] Screws [3] Screws [4] Load cell [5] Stop screw [6] Lock nut [7] Load cell mounting bracket Fig. 19: Removing load cell Î To complete the installation of the load cell it is necessary after installation to pre-stress the load cells. Place a 3 kg weight into the load cell for ten seconds and then remove it. Repeat this procedure three times. Î Re-route and install the wiring from the load cell to the appropriate location in the control box.
Maintenance and Repair 9.6.5 TrueBlend™ TrueBlend Weigh Bin Mount Installation and Adjustment models TB45 and TB100 Follow these steps to install and adjust the weigh bin and/or the weigh bin mount on TrueBlend models TB45 and TB100. Use this procedure to fit a new weigh bin mount to an existing weigh bin or to adjust the clearance between the weigh bin and the weigh bin mount. 1 Remove weigh bin from blender and set aside.
TrueBlend™ Maintenance and Repair 4 The weigh bin mount should slide on easily with no interference between the two pieces but should be tight enough so there is very little movement between the two parts. The movement shown should be minimal – less than .010 of an inch. Movement should be less than 0.010 inch (0.254 mm). 5 Edition: February 2008 If the weigh bin mount will not slide on the weigh bin, the pins that are welded on the back of the weigh bin will need to be adjusted.
Maintenance and Repair 6 If the weigh bin slides on the pins but excessive movement exists (greater than 0.010 inch) as shown in step 4, the weigh bin pins will need to be tightened. To tighten the pins, place the weigh bin on a hard surface and lightly tapping the top of the pins. Each pin should be tapped a couple of times and then step 3 should be tried again. 7 Once the pieces are adjusted correctly, Key hole install the weigh bin edge mount onto the load cell.
TrueBlend™ 9.6.6 Maintenance and Repair Load Cell Removal and Installation for Trueblend models, TB250, TB500 and TB900 ELECTRIC SHOCK! DANGER! High voltages can cause life-threatening currents in the body and injury from electric shock. Î Allow only trained and qualified electrical technicians to work on the electrical system. Î Before any electrical work disconnect the unit from the power supply and lock to prevent unauthorized persons switching it on.
Maintenance and Repair TrueBlend™ Removal. Î Removal of one load cell (both load cells in the unit follow the same procedure) Î Remove the weigh bin Î The load cells are very sensitive and must be handled with care. Make sure that when the load cell is being removed or installed that there is no torque affects applied to the load cell.
TrueBlend™ Maintenance and Repair Î Installation of one load cell (both load cells in the unit follow the same procedure.) Î Position the new load cell (figure 20, item 1) note that notch on the load cell should be facing downward. Place a small amount of removable strength Loctite onto the two screws (figure 20, item 8) and re-attach the new load cell to the load cell-mounting bracket (figure 20, item 11).
Maintenance and Repair TrueBlend™ Î The load cell upward motion stop bolt (figure 22, item 4) and lock nut (figure 22, item 5) most likely were not loosened during removal of the load cell and should not need reset. If they were loosened the gap between the upper load cell stop bolt (figure 22, item 4) and the new load cell (figure 22, item 7) should be set at approx. .005” (use a feeler gauge for value) when the weigh bin is in place and at rest.
TrueBlend™ 9.6.7 Maintenance and Repair Replacing controller Determining blender model See 7.7.3 Input TrueBlend Model. After installing new controller, verify that the blender model designated on the control matches the model number of the blender it is connected to. 9.7 Cleaning The mixing chamber and the material hopper of the unit should be cleaned of all material residues before changing material. 9.7.1 Cleaning material hopper and mixing chamber Î Open the main door. Î Remove the weigh bin.
Decommissioning and Disposalr TrueBlend™ 10.0 Decommissioning and disposal 10.1 Decommissioning the unit Î Switch the unit off. Î Disconnect the unit from the power-supply system. Î Remove the hose for the compressed air supply. 10.2 Disposing of unit parts PERSONAL INJURY AND ENVIRONMENTAL DAMAGE! CAUTION! By incorrect disposal of operating fluids. Incorrect disposal of operating fluids endangers people and damages the environment. Î Dispose of the unit parts and operating fluids sorted and correctly.
TrueBlend™ Appendix 11.0 Appendix 11.1 Menu structure 11.1.1 Operating levels/password level The different operating levels are identified with level 1-3 in the menu structure: • Level 0: for guests • Level 1: for the operator • Level 2: for making settings • Level 3: for the service user See also 7.6 Logging in/logging out.
Appendix 11.1.
TrueBlend™ 11.1.
Appendix 11.1.
TrueBlend™ 11.1.
Appendix 11.1.
TrueBlend™ 11.1.
Appendix TrueBlend™ 12.0 Appendix: Addendum for Retrofit Blenders 12.1 Retrofit Control Blender Start up Procedures When the TrueBlend Controller is used in retrofit replacement applications, follow the initial setup procedure below to ensure your blender will run at its optimum accuracy. This procedure sets the default dosing rates and settling times. This set up will help the blender control “home in” on the actual dosing rate quicker. 1 Determine the valve configuration for the particular blender.
TrueBlend™ Appendix 3 Enter the default flow rates into the blender control on the dosing rate screen. 4 Select the proper default settling times for the different valve configurations from the following table: Table from Product group Example: Blender XYZ Component 1 – 3” X 6” valve – 1.5 s Component 2 – 3” X 6” valve – 1.5 s Component 3 – 2” X 3” valve – 1.5s Component 4 – 2” X 3” valve – 1.5 s Component 5 – 2” i.d. feeder – 5 s Component 6 – 1” i.d.
Appendix TrueBlend™ 13.0 Appendix 13.1 Blow off installation instruction sheet 1 Mark location of hole that will need to be drilled and tapped (see page two for your particular blender size). 2 Remove the level sensor (noting location of adjustment and sensor face), mixing chamber front plate, mixing chamber, mixer, and any wiring that is in the way of drilling the hole. 3 Drill pilot hole at indicated location. 4 Drill 11/32” hole (de-burr hole) and tap 1/8” NPT.
TrueBlend™ Appendix 9 Route item 6 between 5 and 7 and insert. 10 Re-install sensor and wiring. Adjust flow through item 2 so a small amount of air is bleeding from the opening in item 1. Adjust the insertion level and direction of item 1 so the air is blowing across the face of the sensor. Insertion depth into the chamber should be minimal as possible so tube does not contact mixer blade - tighten item 8 on item 1.
Appendix TrueBlend™ 14.0 Appendix 14.1 Replacing the TrueBlend Touch Screen Control 1 Disconnect and lockout the main power supply. 2 Disconnect and remove the existing TrueBlend touch screen control. 3 Install the new control. Turn the main power on. 4 Press the HOME button. The Overview Screen will appear. 5 Press the TRUEBLEND icon. The TrueBlend Status Screen will appear. 6 Press the SETTINGS button. On the Settings Screen, press the icon beside TB Model/Name.
TrueBlend™ Appendix The controls are designed to be compatible with previous product releases. The model and wiring revision will determine if additional changes are necessary before operating your new control. 1 Press the HOME button. The Overview Screen will appear. 2 Press the SETTINGS button. The Settings Screen will appear. 3 Press the ? button beside the words System Information. The System Information Screen will appear. Pre-Rev. E the button is defaulted to OFF.
Appendix TrueBlend™ We’re Here to Help Additional manuals and prints for your Conair equipment Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
TrueBlend™ Appendix Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
