________________________________
Continuous Loss-in-Weight Blenders
with
Allen-Bradley SLC 5/04 Programmable Controller
and
PanelView 600 Touch Screen Interface
Part Number: 882.092698.00
Bulletin Number: BF3-615
Effective: 9/1/08
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2008
All rights reserved.
Credit Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA
number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period and/or
in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA
number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific warranty
terms.
Continuous Loss-in-Weight Blenders
iii
Table of Contents
CHAPTER 1: SAFETY .................................................................6
1-1
How to use this manual...............................................................................................6
Safety symbols used in this manual ......................................................................6
Warnings and precautions...........................................................................................8
Responsibility ..............................................................................................................9
General responsibility............................................................................................9
Operator responsibility.........................................................................................10
Maintenance responsibility..................................................................................11
Reporting a safety defect ....................................................................................11
1-2
1-3
CHAPTER 2: FUNCTIONAL DESCRIPTION............................12
2-1
2-2
Models covered in this manual..................................................................................12
General description ...................................................................................................12
Accessories.........................................................................................................12
Customer service ................................................................................................12
Typical features & components.................................................................................13
Mechanical features ............................................................................................13
Controller features...............................................................................................13
Electrical features................................................................................................13
Blender system component description...............................................................14
Options......................................................................................................................19
Safety devices and interlocks....................................................................................20
2-3
2-4
2-5
CHAPTER 3: INSTALLATION ...................................................22
3-1
3-2
Uncrating the equipment ...........................................................................................22
Rigging and placing the unit......................................................................................22
Site requirements ................................................................................................23
Mounting configuration........................................................................................23
Electrical installation..................................................................................................26
Pneumatic installation ...............................................................................................27
Overall installation (summary)...................................................................................28
Set-up........................................................................................................................29
Load cell adjustment ...........................................................................................29
Final connections ................................................................................................30
Controller setup...................................................................................................31
Scale calibration..................................................................................................31
............................................................................................................................44
3-3
3-4
3-5
3-6
CHAPTER 4: OPERATION ........................................................47
4-1
Start-up......................................................................................................................47
General operation................................................................................................47
Controller description & operation.............................................................................49
Display description ..............................................................................................49
Setting a recipe ...................................................................................................51
4-2
Continuous Loss-in-Weight Blenders
iv
MAINTENANCE..........................................................................52
Preventative maintenance schedule....................................................................................52
APPENDIX..................................................................................54
6-1 Warranty and spare parts .............................................................................................54
Annex B information.....................................................................................................55
6-2 Addendum (Service supervisor information).................................................................55
Programmable settings........................................................................................56
6-3 Technical assistance .....................................................................................................63
Continuous Loss-in-Weight Blenders
v
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
Continuous Loss-in-weight Blender. The purpose is to assist you in applying efficient,
proven techniques that enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the blender. We can also provide the assistance of a factory-trained technician to help train
your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the Continuous
Loss-in-Weight Blender. These instructions are intended to supplement standard shop
procedures performed at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the unit safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your Continuous Loss-in-Weight Blender
provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER!
WARNING!
Caution!
DANGER indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that,
if not avoided, may result in minor or moderate injury or in property
damage.
Continuous Loss-in-Weight Blenders
Allen-Bradley Controls
Chapter 1: Safety
6
Continuous Loss-in-Weight Blender Safety Tags
Tag
Description
Tag
Description
Pinch Point - Slide
Gate
Read Operation &
Installation Manual
Shear Point - Rotating
Mixer or Agitator
Earth Ground
High Voltage Inside
Enclosure
Protected Earth Ground
Lifting Point
PE
Shear Hazard -
Rotating Auger
Continuous Loss-in-Weight Blenders
Chapter 1: Safety
7
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following pertinent local and national codes. This may include,
but is not limited to OSHA, NEC, NFPA, CSA, UL, CE, SPI, and any other local, national
and international regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Keep fingers away from slide gates, augers, clean-outs, and calibration hatches.
Automatic operation may start unexpectedly, A PINCH HAZARD CAPABLE OF
CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power and compressed air before servicing or maintaining
the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
Continuous Loss-in-Weight Blenders
Chapter 1: Safety
8
1-3 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.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel
must realize that safety is always a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
Continuous Loss-in-Weight Blenders
Chapter 1: Safety
9
Operator Responsibility
The operator’s responsibility does not end with efficient production. The operator usually has
the most daily contact with the equipment and intimately knows its capabilities and
limitations.
Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.
REMEMBER:
• 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.
• NEVER try to pull material out of the blender with your hands while it is running!
• Before you start the blender check the following:
o Remove all tools from the unit;
o Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
metering or mixing area;
• If your blender has been inoperative or unattended, check all settings before starting
the unit.
• At the beginning of your shift and after breaks, verify that the controls and other
auxiliary equipment are functioning properly.
• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,
or remove safety guards. Such alteration is not only unsafe, but will void the warranty
on your equipment.
• When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
• Report the following occurrences IMMEDIATELY:
o unsafe operation or condition
o unusual blender action
o leakage
o improper maintenance
• NEVER stand or sit where you could slip or stumble into the blender while working
on it.
• DO NOT wear loose clothing or jewelry, which can be caught while working on a
blender. In addition, cover or tie back long hair.
Continuous Loss-in-Weight Blenders
Chapter 1: Safety
10
• Clean the blender and surrounding area DAILY, and inspect the machine for loose,
missing or broken parts.
• Shut off power to the blender when it is not in use. Turn the switch to the OFF
position, or unplug it from the power source.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on a blender above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk around your
blender, use it. The work platform should have secure footing and a place for tools and parts.
DO NOT climb on unit, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the blender until all persons are clear of the area. DO NOT start and
run the unit until you are sure all parts are functioning correctly.
BEFORE you turn the blender over to the operator for production, verify all enclosure
panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
Continuous Loss-in-Weight Blenders
Chapter 1: Safety
11
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for continuous
loss-in-weight blenders of various blending rates and specifications. See Figure 1 below for a
list of available models and specifications.
Figure 1: Models Covered by this Manual (√ - Denotes Availability)
Model
015
060
100
Blending Capability
2 components
3 components
4 components
5 components
6 components
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Maximum blending rate in lbs./hr (kgs./hr) ℵ
750 (340)
3000 (1360)
5000 (2270)
ℵ Actual rates will vary. Consult the factory for guaranteed blending rates.
Model numbers are listed on the serial tag. Make sure you know the model and serial number
of your equipment before contacting the manufacturer for parts or service.
Blending systems are as varied as the applications they are designed for. All continuous loss-
in-weight blenders are sized to meet the specific requirements stated by the customer at the
time of purchase, and future changes my require a modification to the original system.
2-2 General Description
All blenders are designed to blend plastic pellets and regrind, and supply the blended material
to the extruder. The standard system is not designed to blend powder or any other no-free-
flowing materials. Consult the factory if your future process requirements require the
addition of these materials.
Accessories
The manufacturer offers a variety of options for these blending systems, including mezzanine
stands, agitated regrind supply and weigh hoppers, etc. All accessories are designed and
manufactured to ensure proper results for your application.
Customer Service
The intent of this manual is to familiarize the operator and maintenance personnel with these
blenders and help your organization get the maximum service from your equipment. If you
have any questions regarding installation, service, repair, custom equipment, or applications,
please do not hesitate to contact us for the information required. Prices for additional
equipment, accessories, or repair parts will be furnished promptly upon request.
Note: If you desire to use a blender for an application other than that for
which it was purchased, please contact your sales representative or our
factory to verify compatibility of the equipment with the new process.
Misapplication of the equipment could result in injury to the operator
or damage to the equipment.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
12
2-3 Typical Features & Components
Mechanical Features
• Blender automatically adjusts individual feeders to match learned extruder rate at the
ratio required.
• Upper material supply hoppers with conical re-fill valves and dust boots.
• Individual ingredient weigh hoppers with clear side walls.
• Cast aluminum feeder housings with drains.
• Lower mass flow weigh hopper assembly with clear side wall.
• Cascading mixing section.
1
• Precision /10% span accurate cantilever load cell weighing system
• Yasakawa GPD 205 variable frequency drive (VFD) system with ¼ hp inverter-duty
(brushless) AC motors
• Motor drive panel – NEMA enclosure
• Machine-mount spool flange with drain
• Hopper lids arranged for manufacturer and non-manufacturer receivers and loaders
Controller Features
• Color Allen-Bradley PanelView 600 color touch screen
o
o
o
o
o
Easy menu-driven format
Serial printer port
Recipe storage book
Inventory and material usage information
OPTIONAL Ethernet communications module
• Manual operation capabilities, for emergency use in case of processor failure
Electrical Features
• Inductive proximity switch for extruder speed (you may also write extruder speed
through Ethernet in lieu of using the proximity switch)
• 115/1/50 or 60 supply voltage
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
13
Blender System Component Description
This section describes the various components of the continuous blending system. The
continuous blending system is made up of the following components (See Figure 2 below):
• Ingredient supply/re-fill hoppers
• Ingredient weigh hoppers
• Ingredient metering auger assemblies
• Cascade material chute
• Lower mass flow weigh hopper
• Control panel
• Motor drive panel
• OPTIONAL “Quick color change” kit
Figure 2: Continuous Blender Assembly
Ingredient Supply/Re-fill Hoppers
The ingredient supply/re-fill hoppers are located on top of the blender frame. Their purpose is
to provide a supply of material to the individual ingredient weigh hoppers on demand. The
hoppers are equipped with an air-operated discharge valve that is opened by the PLC when a
respective weigh hopper needs a re-fill of material. These hoppers are sized to handle the
percentage requirements of the ingredients. Optional level sensors which might exist in these
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
14
hoppers are not controlled nor read by the blender. Their existence is solely for the use of a
low level alarm to be wired into a separate controller. These would not be present on a
standard blender.
The hoppers may be equipped with a polycarbonate sight glass. This is mounted in the upper
cone section of the hopper. This is useful for a quick reference of the material level in each
hopper.
The supply/re-fill hoppers should be vented to the atmosphere through the louver located on
the lid of each hopper. This louver is required to prevent the loading system from creating a
vacuum in the hopper, which would prevent material from flowing out properly. This
situation could be caused by a leaking discharge seal on the vacuum receiver.
Ingredient Weigh Hoppers
Each ingredient weigh hopper assembly consists of a conical mass flow weigh hopper, a
precision load cell and a discharge tube disc seal. A mass flow weigh hopper is a steep
degree conical hopper with vertical side walls with a discharge tube on the bottom. Each
weigh hopper is sized to the blender ingredient metering requirements. This assembly is
responsible for weighing the material ingredients as they are metered out by the metering
auger assemblies located below each weigh hopper. The manufacturer believes this is the
best way to weigh free flowing pelletized materials. This design allows the hopper to weigh
only the material and nothing else, unlike other systems that weigh the heavy auger
assemblies. This design eliminates extra variables, such as auger drive vibrations, etc. from
the weighing system and increases the load cell resolution. Each weigh hopper will be
refilled periodically as material reaches the preprogrammed low weight setpoint for that
hopper. Clear hopper side walls or sight glasses are provided on each on the weigh hoppers
to allow the operator to monitor the levels.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
15
Ingredient Metering/Transport Auger Assemblies
Each metering auger assembly consists of a:
• Cast aluminum motor mount
• Cast aluminum feeder body
• Aluminum feeder tube
• Gearbox
• Inverter-duty AC drive motor
• Machined metering auger
The metering auger assembly accurately meters the material from the ingredient weigh
hopper at the calculated rate.
The mass flow weigh hopper design allows more range of the load cell to be used for actually
weighing the material and eliminates dynamic drive movement and vibrations from affecting
the load cell readings.
Figure 3: Metering Auger Components
Cascade Material Chute
The cascade material chute is a rectangular conduit in which all the metering augers
discharge. The materials are cascaded together and directed vertically down into the lower
mass flow weigh hopper. A clean out door is provided on the chute above the augers, so that
any dust can be blown out if it has collected.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
16
Lower Mass Flow Weigh Hopper Assembly
The lower mass flow weigh hopper, otherwise known as the weighed common hopper, is
used to determine the actual processing rate of the processing machine so that the blender can
be slaved in to run at the learned rate. The hopper is constructed of spun aluminum and is of
the mass flow type (See the glossary in the Appendix). It is supported by a load cell, and will
carry a weight of material depending on how much is flowing into the hopper from the
metering augers, and how much is flowing out of the hopper, dictated by the processing rate
of the processing machine.
The computer uses the mass flow hopper flow rate (the differential rate), along with the
known total rate from the weight loss feeders to determine the actual processing rate of the
processing machine. The blender output rate is then adjusted to match the learned processing
rate. This method of operation provides very accurate slave in of the blender to the
processing rate, and eliminates the need for a mixing hopper.
The lower common weigh hopper is also equipped with a high level proximity level sensor to
allow manually adjusted volumetric operation of the blender in the event of computer failure.
Figure 4: Weigh Hopper Assembly
Note: The lower or common mass flow weigh hopper uses the change in weight over
time, of material contained in the hopper over time to calculate it’s discharge
rate (differential rate). This learned discharge rate is then summed with the
known total metering rates of the blender feeders to learn the actual processing
rate of the processing machine. The blender output rate is then adjusted to
match the learned processing rate, eliminating the need for a blender mixer.
“Fixed Rate” mode
The lower mass flow weigh hopper may be replaced by a collection hopper with “high” and “low “
level switches on higher capacity blenders. This configuration controls the blending system rate
based on material level rather than material weight.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
17
PLC Control Panel
The PLC control panel may be mounted on the side of the blender frame, or remote mounted
near the blender. It uses an Allen-Bradley SLC 5/04 programmable controller with standard
24 vdc input output cards. This design provides excellent blender performance along with
easily replaceable off-the-shelf parts in case of any electronic component failure.
Touch Screen Interface
The PanelView 600 color touch screen display can be mounted up to 50 feet (15 m) from the
PLC control panel. It is very user friendly after installation and setup, simply enter in the
proper recipe and start the blender.
If it is desired to have a local display and control of the blender at the operator station, an
optional PanelView 600 can be installed.
Motor Drive Panel
The auger motor drive panel is mounted on the blender frame adjacent to the PLC control
panel in most applications. The motor drive panel is permanently wired on the blender. The
standard panel contains Yaskawa GPD 205 variable frequency motor drives, a power supply
and manual volumetric backup system wiring components.
The motor drives on the blender are standard, off the shelf drives and are readily available
from Yaskawa distributors and the manufacturer.
Power cords to each drive motor are equipped with plugs to facilitate auger removal and
motor replacement, if necessary.
Optional “Quick Color Change” Kit
The optional “QCC” quick color changeover kit allows the virgin material to be gravity fed
so the processing machine can be operated, while a color change is being done.
The virgin material auger metering assembly is equipped with a lower slide gate and
discharge tube. A flexible hose connects the discharge tube with a cast aluminum flange
below the blender that is equipped with an angled inlet tube stub. When the slide gate is
opened, virgin pellets will gravity feed to the bottom of the blender and bypass the blender
augers and the lower mass flow weigh hopper, allowing the extruder to be operated.
The blender augers can then be removed and the colors changed without the processing
machine having to be “re-strung”, and the product having to be re-gauged.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
18
2-4 Options
The following is a list of options, which your blender may have been equipped with:
•
•
Mezzanine stand with slide gate and 4” tube stub.
Low-level proximity switches. Detects material supply shortages for each
supply hopper before blender runs out (Requires a separate, remote mount alarm
panel with its own lights, horn and silence button).
•
•
•
•
•
Supply hopper lids for non-ACS supplied vacuum receivers & loaders.
Agitated, straight wall regrind supply & weigh hoppers for regrind material.
Compressed air loader for low percentage additives.
Ethernet communication module
Remote Display
Allows control of blender from a second location up to 50 feet (15 meters) away. The remote
display can be located in another location to allow the blender to be operated from that
position. The additional remote PanelView 600 operates identically to the main display.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
19
2-5 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
continuous loss-in-weight blender. This manual is not intended to supersede or alter safety
standards established by the user of this equipment. Instead, the material contained in this
section is recommended to supplement these procedures in order to provide a safer working
environment.
At the completion of this section, the operator and maintenance personnel will be able to 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. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the continuous
loss-in-weight blender; however, it is the responsibility of the personnel operating and
maintaining the equipment to familiarize themselves with the safety procedures and the
proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be run.
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
20
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on the continuous loss-in-weight blenders are primarily concerned with electrical power
disconnection and the disabling of moving parts that may need to be accessed during the
normal operation of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, disconnect plug, lever or a handle. Within
this lockable handle, there may be a location for a padlock. A padlock should be placed in
the lockout handle by personnel servicing the equipment.
WARNING! At no time should anyone other than the person who installed the lockout or
unplugged a twist plug, remove the lockout, or reconnect the twist plug.
Pluggable Line Cord
This line power cord allows the operator or maintenance personnel to unplug the blending
system from its power source and tag it out. This plug may be tagged with any number of
approved electrical lockout tags. These tags are available at most electrical supply stores.
Amphenol quick connect Plug Connected to Each Auger Motor
The plug must be unlatched and the female end of the cord removed from the motor plug.
This disables the motor from turning while the auger unit is being serviced or cleaned. The
motor cords are cut to length so they must be disconnected before the auger can be removed
from the housing.
Note: Disconnect both of the items listed above before cleaning or servicing
equipment.
Figure 5: Plug
Caution!
Disconnect the electrical power and compressed air source before working
on the equipment!
Continuous Loss-in-Weight Blenders Chapter 2: Functional Description
21
Chapter 3: Installation
3-1 Uncrating the Equipment
Continuous loss-in-weight blenders are shipped bolted on a skid, enclosed in plastic wrap,
and contained in a wood crate.
1. Remove the crate from around blender.
2. Secure strap of proper lifting capacity to the lifting lugs installed in the holes
provided.
Caution!
Use approved safety straps or chains to lift the blender from the eyebolts on
the top plate (See figure 6 below for eyebolt positioning).
Figure 6: Lifting Eyebolt Position on Blender
Caution!
Remove hoppers if necessary to prevent damage.
3. Lift blender until strap is taut.
4. Remove bolts attaching bottom of blender to shipping skid.
5. Raise the blender slowly.
3-2 Rigging and Placing the Unit
It is the intent of this section to familiarize the reader with the proper site requirements and
installation procedures of the continuous loss-in-weight blending system. The information in
this section is NOT meant to replace or supersede an established local or company
implemented procedures. It is meant to enhance them.
Note: The manufacturer assumes NO responsibility for any damages resulting from
improper installation, or improper handling during the installation process.
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Site Requirements
This section describes site requirements in detail. These requirements are broken down into
mechanical mounting, electrical connections and pneumatic connections. Since the
continuous loss-in-weight blender is available in several different mounting arrangements, it
is necessary for the reader to become familiar with the different arrangements.
Mounting Configuration
The continuous loss-in-weight blender is available in (3) three basic mounting arrangements.
They are:
• Machine Mount
• Mezzanine Mount
• Floor Mount
Machine Mount
In a machine mounting application of the continuous loss-in-weight unit, there are a few
items to review before placement and mounting of the blending system begins.
First, verify the machine flange dimensions match the continuous loss-in-weight blender
flange or the optionally provided adapter flange dimensions.
Verify that the machine material inlet flange is mechanically capable of supporting the weight
of the continuous loss-in-weight blender with a full load of material and the loading system
installed.
Note: While in operation, the continuous loss-in-weight blender applies horizontal
and vertical pressures to the mounting flange. The vacuum system will cause
some shaking due to the dynamics of the conveying operation.
Note: If there is a question as to the mechanical stability of a mounting flange, the
appropriate reinforcements and lateral supports must be provided to ensure a
safe installation. Check to ensure that the unit is braced to prevent swaying if
necessary. Contact the manufacturer.
Verify all clearances on the top and beside the processing machine. This is to insure that all
motors, hoppers, control panels, etc. have adequate room for proper operation and servicing.
Note: Allow at least 24” clearance around auger assembly to provide adequate room
for cleaning, servicing, etc.
Using proper lifting equipment, lift the blender into place above the machine throat and
secure the flange bolts. Check to ensure that the unit is properly oriented, and that there is
adequate access around the blender for operating and servicing of the panels and cleaning of
the feeder units. A work platform with OSHA approved handrails is recommended.
Take care to insure proper orientation with adequate access to operator controls, mix
chamber, and metering units.
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Note: Never weld on the blender’s frame, machine or mezzanine
without first removing the control panel and verifying that the
blender’s power is disconnected.
Mezzanine Mount
In a mezzanine mount application, review the following items before installation begins.
First, verify the blender mounting locations match the mezzanine supports. Verify that the
mezzanine is capable of supporting the blender with a full load of material and loading
equipment installed. If the unit is unstable in the vertical or horizontal plane, additional
bracing of the mezzanine floor or blender side bracing will be required. Remember that this
is a precision weighing system. It is only as accurate as the base it is mounted on.
If a blender is moving due to vibration, the weigh hoppers will tend to remain stationary due
to the laws of physics dealing with inertia. This causes the load cells to output erroneous
weight signals.
Note: While in operation, the blender applies both horizontal and vertical pressures
to the mezzanine mount location.
Second, verify ALL clearances to other equipment and structures. Insure motors, hoppers,
and control panels have proper clearance for operation, cleaning and maintenance.
Note: Auger assemblies require a minimum of 24 inches for proper cleaning and
maintenance.
Ensure that the blender, if feeding the extruder from an offset (not exactly over the center of
the extruder throat), is mounted with the gravity discharge tube at least at a 60 degree angle
(See figure 7 below). This must be more than the angle of repose of the material or bridging
in the discharge tube will occur and the extruder could starve. The material connection
should be made with rigid tubing, if possible.
Figure 7: Offset Mezzanine Mount Position
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Note: Ensure that the feed tube angle is steep enough (60 degrees is recommended).
Note: Some mezzanine mount applications will require the blending system’s lower
mass flow hopper be mounted on the extruder throat. The metering section
will be mounted on a small stand on the mezzanine directly above the extruder
with a 4” tube stub for gravity metered flow.
Note: This arrangement will be similar to the floor mounted configuration, discussed
in the following section, less the blower assembly.
Using the proper lifting equipment, lift the blender into place. Take care to ensure the proper
orientation of the blender and operator controls.
Note: The manufacturer assumes NO responsibility for any damages resulting from
improper installation or improper handling during the installation process.
Once properly positioned, securely fasten the blending system to the floor.
Floor Mount
In a floor mounting application, ensure adequate clearance for all blender operations and
maintenance. The operator and maintenance personnel must have access to all parts of the
blender. If necessary, it is the customer’s responsibility to provide adequate, safe work
platforms around the blender to meet state and local safety codes. For specific dimensions,
refer to the assembly diagram provided with each blender.
Note: Auger assemblies require a minimum of 24 inches of clearance for proper
servicing and cleaning.
Insure the chosen location for the blending system is adequately away from high traffic aisles.
Insure that normal day to day operations will not place the blending system at risk of damage.
Once a proper location has been chosen, securely fasten the blender floor stand frame to the
floor.
Note: The blending system MUST BE SECURELY LAGGED TO THE FLOOR before
operating the unit.
The floor mounted version has a blower and venturi that continually conveys the metered
blend to the processing machine mounted mass flow weigh hopper. The blower unit can be
placed in any position around the venturi and connected with a flexible hose. It is provided
for a straight hook up from the factory, but this can easily be field changed to any convenient
location, with additional tubing and a longer wiring conduit. These blenders have been
installed with the blower remote from the blender and connected with rigid aluminum tubing,
bends and Morris couplers. This is the customer’s preference. All conveying tubing is to be
provided by the customer and is not included with the blender pricing.
If the remote mass flow weigh hopper is located more than 25 feet from the blender control
panel, a load cell amplifier module may be required.
Note: The manufacturer assumes NO responsibility for any damages resulting from
improper installation or improper handling during the installation process.
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Figure 8: Typical Layout for a floor mounted blender
3-3 Electrical Installation
The continuous loss-in-weight blending system is designed to operate on 115 volt, single
phase, 50 or 60 hertz AC power. The power requirements will vary with the blender’s size
and throughput rating. For exact current requirements, check the blender serial number tag,
located on the blender motor control panel.
As an added option, the manufacturer may provide a voltage transformer for special supply
voltage. If supplied, they are rated for the load required by the blending system - no other
equipment should be connected to the transformer. The additional equipment may induce
noise into the power circuit to the blender, as well as possibly overload the transformer.
The power transformer wiring and mounting is the responsibility of the customer. If
company or local codes require fusing or disconnects, these items must be supplied, wired,
and mounted by the customer.
Each blending system MUST be connected to a separate source of power. Do not connect
extra equipment on the same line, with or without use of the transformer.
It is the customer’s responsibility to ensure that the power requirements of the blending
system are satisfied.
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3-4 Pneumatic Installation
The blending system utilizes air pneumatics to perform the re-fill function on the ingredient
weigh hoppers.
The manufacturer provides all pneumatic plumbing to a single ¼” standard pipe thread
fitting. The blender requires a maximum of 60 PSI of compressed air.
It is the customer’s responsibility to ensure that the air is CLEAN, DRY & LUBRICATED.
Any component failures due to airborne contaminants will not be subject to warranty
consideration.
The working range of the air pressure is from 40-60 PSI. PSI lower than 40 may result in
shutoff valve failure. PSI greater than 60 may result in damage to the plunger cones in the re-
fill hoppers. A 5 micron filter is recommended.
Note: It is the customer’s responsibility to provide proper air pressure regulation,
filtration, and lubrication devices.
Figure 9: Pneumatic Air System
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3-5 Overall Installation (Summary)
This installation procedure should be used as a general guideline for the proper installation
steps required to install the continuous loss-in-weight blending system.
1. Visually inspect the extruder or blender mounting location for obstructions.
2. Remove the material supply hopper on the extruder flange.
3. Carefully lift blender into place above the mounting flange on the extruder and fasten
the blender to the flange using the extruder flange bolts.
Note: Always lift the blender from the eyebolts on the top plate.
4. Mount the weigh hoppers that were shipped in boxes on the crate, to their respective
load cells (Don’t forget the plastic dust cover on the bottom of the weigh hopper).
Align the discharge tube on the weigh hopper to be centered in the lower frame
opening over the feeder assembly. Use caution in tightening the bolts. Adjust the
gap to 0.040”.
5. Hook the manual mode level sensor bracket over the lower mass flow weigh hopper
on the bottom of the blender. Ensure that the cord is not binding on anything that
would affect the accuracy of the weigh hopper.
6. Check the wiring from the load cells to the control panel.
7. Ensure that the motor power cords are connected to each of the metering unit motors.
Note: Ensure that the augers on the blender metering units are not bent or damaged
in shipping before starting the unit.
8. Connect the control power to the motor control panel.
9. Connect the compressed air piping to the inlet fitting on the top of the blender top
frame. Ensure that the air supply is regulated to a maximum of 60 PSI.
Note: Ensure that the compressed air is regulated to 60 PSI max.
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3-6 Set-up
This section will discuss the mechanical setup and control system setup of the continuous
loss-in-weight blending system. After reading this section, you should be familiar with the
mechanical setup and the electronic control setup of the blending system.
Load Cell Adjustment
The mechanical setup of the continuous loss-in-weight blending system involves the
adjustment of the weigh hopper load cells (Please refer to the figure below). This figure
illustrates the proper adjustment of the load cell mechanical stop bolt. The setting for the
positive stop is necessary to prevent the load cell from being “over-ranged” by excessive
loading on the weigh hopper. The setting for the load cell stop is forty thousandths of an inch
maximum (.040”). This should be set by a feeler thickness gauge with the weigh hopper
empty.
If a feeler gauge is not available, the weigh hopper should be filled with the material that is to
be blended, and the stop adjusted so there is just a very small gap (a couple of sheets of
notebook paper) between the load cell, and the blender base stop. This will allow the load cell
to operate without mechanical restrictions and provide an overload safety. To adjust the stop,
adjust the screw located on the bottom of the load cell. Adjust the screw up to increase the
gap and down to decrease the gap.
Note: THE WEIGH HOPPER ASSEMBLY MUST BE FREE FROM FRICTION,
WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD
CELL ITSELF.
Figure 10: Load Cell Mechanical Stop Adjustment
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Final Connections
1. Connect the blender to the appropriate power source.
2. Connect the compressed air piping, ensuring that a 5-micron air filter is installed,
along with the proper water trap, and lubrication unit, if required. Verify that 60 psi
(4.14 bar) of clean, dry compressed air is supplied to the blender.
Note: Again, make sure that proper air supply connections are made to the blender,
as dirty, contaminated, wet air can damage blender components and can
quickly cause poor performance and accuracy!
Note: Make sure that the blender is supplied with clean, dry,
60 psi (4.14 bar) compressed air.
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Controller Setup
This section describes the proper setup of the continuous loss-in-weight blending system
control parameters. These parameters are operator changeable; however, these items should
only require setup during the initial installation. Only authorized personnel should change
them. For security reasons, the menu that is used to access these parameters is password
protected.
Many of the variables and setup parameters have been preset at the factory and do not need to
be changed. However, this section of the manual will address all of the blender setup
parameters that were available at the time of printing. The purpose of this is to familiarize the
reader with all the setup parameters and their usage.
The following parameters will be discussed:
9 Changing Recipes
• View Recipe
• Change Recipe
• Recipe Book
9 Hopper Setup
• Set Hopper Size
9 Calibration
• Scale (Hoppers)
• Feeder
• Service
• ACS Only
9 Units
• Metric or Standard
FIFO Diagnostics
• Mass Flow
9
• Feeder
9 Network Information
9 Alarm log
9 Alarm Setup
9 Password
• User
Scale Calibration
The heart of the blending system is the load cells. They monitor the weight in each of the
ingredient weigh hoppers and the lower mass flow weigh hopper. As the load cells are reading
the actual material weight loss that is removed from the weigh hoppers by the feeders or the
extruder, the proper calibration of these load cells is essential for the correct operation of the
blender. This calibration must be performed upon initial installation and startup of the blender.
They should also be rechecked periodically with a calibration weight to ensure that they have
not been damaged in the normal routine of cleaning, color changes, etc.
The calibration of each load cell is done by using two points on the output of the load cell scale.
The first of these points is known as the “Tare Weight”. This is the weight of the empty hopper
assembly on the load cell. This is also known as the zero weight point (starting point) of the
scale. This zero or starting point must be initialized with an empty weigh hopper. There must
be no binding or leverage put on the load cell.
The second weight point that will be used in the load cell calibration procedure is a known
amount of weight for the weigh hopper. Provided with the blending system is a calibration
weight. The calibration weight is stamped with its actual weight on top. If this is not available,
any object with a known accurate weight to the nearest 1/100th of a lb. in the 5 – 10 lb. range
Continuous Loss-in-Weight Blenders
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will suffice. The weight will be in pounds, unless the blender is provided for metric display
operation (kilograms).
Given the two weight points on the load cell scale, the controller will be able to determine any
other weight on the load cell span. This is limited to the maximum capacity of the load cell.
The standard load cell used on these blenders have a span accuracy of 1/10th %.
The maximum capacity of each load cell is clearly marked on the fixed top of the load cell.
This value will be indicated in kgs. (2.2 lbs. = 1 kg.)
Figure 11: Blender Calibration Weight
Scale Calibration
During the initial setup of the blenders, the feeder units will need to be setup. Most of these
items should have been setup at the factory before the unit shipped.
To calibrate the scales on each of the feeder units, follow the instructions below:
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Touch the “ACS Group” logo in the upper left hand corner. You will be prompted to enter a
password - it is “5413”.
You will see the “Password Accepted” screen, now press “OK”.
Touch the “Calibration” button.
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Touch “Scale” button
Find your calibration weight that shipped with the blender and locate the Weight information
stamped on the weight proceed as follows.
1. Enter weight value stamped on the weight in Cal Wt Box.
2. Make sure weigh hopper is empty then touch Set Zero.
3. Hang Calibration weight on weigh hopper and touch Set Cal Wt.
4. Repeat for all Hoppers including Mass Flow.
5. Touch done when complete
You can also check the calibration by looking at the in LBS box and hanging your calibration
weight on the weigh hopper to be checked.
Feeder Calibration
This section will explain how to calibrate the feeders on your OL blender. This must be done
on initial startup and whenever material is change and bulk density varies greatly. You must
make sure that the feeder to be calibrated has resin available. ****Also note that resin will be
dispensed into the Mass Flow hopper during this procedure.****
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Touch the “ACS Group” Logo. Then enter password “5413”.
Touch the “OK” button.
Touch the “Calibration” button.
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Touch “Feeder” button
Feeder Calibration is carried out as follows:
1. Select the feeder you want to calibrate and enter the value in Feeder# by
touching the adjacent box.
2. Determine the calibration weight and enter it in the box for Cal Wt. (This should
be about 10% of the hopper size.)
3. Enter the Calibration speed by touching the box adjacent to Cal Spd. (This
should be 60)
4. Touch the Press Here to Begin Box. The selected feeder will now start
dispensing resin until it reaches the calibration weight entered above.
5. Pressing Abort will stop the calibration if you have a problem.
6. Repeat this process for all feeders.
It is possible to forgo calibration after the initial calibration is complete if you note down
the calibration values listed in the CAL VALUES box. If you are changing back to a
calibrated resin simply touch the box under Cal Values and enter the appropriate number.
Setting Hopper Size
As the blenders are provided in several sizes and output ranges, the system will need to know
what size all of the weigh hoppers are on the blender.
The following is a reference guide for setting the hopper sizes. The hopper size can change
based upon the material’s bulk density. After a weight has been assigned to the hopper, it
should be monitored the first time it is filled to check the level. The hopper size can be
adjusted, depending upon whether the level in the hopper is too high or too low. Keep the
hopper level full at least 2 to 3 inches below the upper surge hopper refill valve.
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Figure 12: Hopper Sizes
Hopper Diameter
Approximate Hopper
(inches)
Capacity
(@35 lbs. / cu. ft.)
9
12
14
20
24
7
14
18
40
60
Above lists standard sizes and can vary depending on the blender requirements and rates to be
blended. Larger hopper sizes are available on custom order.
Setting hopper size
Touch the “ACS Group” logo and enter password “5413”.
Touch the "OK” button.
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Touch “Hopper Setup”
Touch the box next to the hopper number that you want to change and enter weight value.
Setting Passwords
There are three levels of password security for the control system.
- User (factory set to “5413”)
- Service
- ACS only (cannot be changed factory set to “3145348”)
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To change a password proceed as follows:
Touch the “ACS Group” logo.
Enter password and touch “OK”.
Touch “User Password”
Continuous Loss-in-Weight
39
-Enter original password.
-Touch box next to select operator until you see the level you want to set. (operator, service)
-Touch New Password and enter your new password
-Touch Verify Password and verify you new password
Alarm Setup
There are several alarms in the blender control they are as follows:
No Flow -
No weight loss is being detected on the feeder in question. This would
indicate a faulty load cell, a material bridge in the re-fill hopper or
something obstructing load cell movement.
Re-fill too long -
No material -
Weigh hopper is not being re-filled in the allotted time. This would be
caused by the supply hoppers not be kept full. Check the loading system.
This means the weigh hopper is empty.
Load cell Failure - The controller is not properly reading the load cell. Check the load cell.
Load cell over ma x- The maximum weight limit on the load cell is exceeded. Check weigh
hopper size and material bulk density.
Extruder No Flow - No weight-loss is being detected in the Mass Flow hopper. Make sure
there is no material bridge above the extruder throat, or interference with
the Mass Flow load cell.
Blender Cannot keep up - The extruder is running faster than the augers will allow the blender
to run.
There are several options to set for the above listed alarms. The following explains the options
and how to set them up.
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First you must get to the Alarm Setup Page. To do this;
Touch the “ACS Group” logo.
Enter the password and touch “OK”
Touch “Alarm Setup”.
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41
All alarm parameters are selectable.
If you do not want to use an alarm for a feeder, ensure the corresponding box has an “N” in it.
To be enabled, the box must have a “Y” in it.
You can also decide to let the Blender continue to Run or Stop if an alarm is active. To do this,
select “Stop” or “Run” in the boxes on the right.
“Pop-ups enabled” means the alarms will be shown on the screen. Select “Pop-ups disabled”
if you don’t want to see the alarms on the screen.
“Extruder flow alarm” and “Blender cannot keep up alarm” can be enabled or disabled
according to costumer requirements.
Communications
All Allen-Bradley Loss-in-weight blenders can be setup to communicate to a host via Ethernet,
an optional Ethernet module must be purchased to allow communications. This can be used for
loss-in-weight extrusion control or for data monitoring. The window below shows how to set
up the 1761ENI Ethernet module.
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Setting Blender for English or Metric
Touch the “ACS Group” logo.
Enter the password and touch “OK”.
Touch “Units”.
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Touch the box that says “English Units” to toggle between English and Metric ****Note, you
must re-calibrate the blender and reset the inventory values if you change this value.***
How to use FIFO Diagnostics
First you must get to the FIFO screen.
Touch the “ACS Group” logo.
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Enter the Password and touch “OK”
Touch “FIFO Diagnostics”
Select “Mass Flow FIFO Data” or “Feeder FIFO Data”
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The Following screens will appear. This data is provided for trouble shooting blender stability
problems. If you are not getting a steady system indication or if you are getting an unstable
system alarm you can check here for the problem. This is a first in first in first out table. It
takes an average and gives you a percent differential. If the steady flag is a “1”, the hopper is
steady. If it is a “0”, it is not steady. This means that the percent differential is greater than
what the value is set to on the advanced hopper page. The mass flow FIFO works the same
way, only you have to calculate the % differentially manually.
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Chapter 4: Operation
4-1 Start-up
The objective of this chapter is to familiarize the reader with the blender’s recipe menu, run
mode operation and displays. Upon completion of this chapter, the reader will be familiar with
the recipe and run mode displays that are available on the continuous blending system.
The various sections within this chapter will be:
• General Operation
• Run Mode Display
• Recipe Menu
All personnel operating the blending system should read this section of the manual BEFORE
operating the blending system.
General Operation
The general operation of the Continuous blending system is as follows: Once the system is
properly installed and set up, the system will be ready for operation. Please see the Installation
and Setup chapter in this manual for further information.
Using the recipe menu, enter a valid recipe. After entering a recipe, the operator will startup
the blending system. This will begin the general operation of the blending system.
Note: Before starting the blending system, each ingredient hopper in the recipe MUST
contain material.
Once the operator initiates the run mode of operation, the blending system controller will start
the metering devices. The metering units will start out at the maximum metering rate at speeds
based on the feeder calibrations that were learned during the prior setup of the blender. The
blender will output the maximum rate that is achievable with the feeder sizes, and the recipe
percentage that is entered in the current recipe. Each metering unit will meter its material out
of its respective weigh hopper at the correct rate to achieve the programmed blend ratio, and
discharge it into the cascade material chute above the lower mass flow weigh hopper.
The metered ingredients cascade together into the weighed common hopper. The PLC looks at
the weight change in the weighed common hopper over time, and learns “The discharge rate
from the common weigh hopper to the processing machine.” This “Discharge rate from the
common hopper to the processing machine” is the learned rate that occurs internally within the
weighed common hopper, and is the difference between the rate of material entering into the
top of the common hopper and the rate of material flowing out of the bottom of the common
hopper. The learned “Discharge rate from the common hopper to the processing machine”, is
added to the known total discharge rate from the blender weigh hoppers. The sum of these two
rates calculates the actual flow rate out of the bottom of the blender. This is the processing rate
of the processing machine that the blender is mounted on.
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The blender will blend at a maximum rate when the lower mass flow weigh hopper has a very
low weight of material. As the weight of material increases in the mass flow weigh hopper, the
controller will adjust the blender feeders output to match the calculated processing machine
rate. The blender will adjust in so that it is running a very closely matched rate to the extruder
and readjust the ingredient hopper outputs accordingly.
The processing rate and the blending rate displayed on the blender control will not match
exactly for any extended period of time as the dynamics of the extrusion process produces a
continuously changing rate for the extruder. The blender will follow this dynamic changing
rate very closely. The learned processing rate is accurate enough for mono-layer extrusion
yield control or co-extrusion layer thickness control.
If the extruder is slowed or stopped suddenly, the blender will reach the high weight point in
the lower mass flow hopper, slow down, and stop the metering devices so the weigh hopper
will not overfill.
Manual Backup Control System
Every continuous blender is equipped with a secondary manual backup control system. This
allows the blender to be switched over to manual operation. In this mode, the feeder speeds are
adjusted manually, and the blender will run, blending volumetrically. The lower mass flow
weigh hopper is equipped with a proximity sensor mounted on the upper level of the hopper.
This is for the manual operation to cycle the metering augers if the level of material in the
weigh hopper reaches a high level.
This secondary control will allow the blender to be operated to provide production in the event
of a control failure. After correction, the blender can be switched back into automatic
operation.
When the blender is running in steady automatic mode, simply check the motor voltages (or)
frequency readouts and record them. Then the drives can simply be “dialed in” for emergency
volumetric operation.
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4-2 Controller Description & Operation
Display Description
The controller on the continuous loss-in-weight blender, utilizes a LCD touch screen display.
Figure 14: Typical Controller Display
A typical menu entry is shown in the figure above.
Please refer to the blender menu structure shown in Figure 13 on the next page. This figure
shows a standard menu structure for the blending system.
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Figure 15: Blender Menu Structure (Standard Unit)
Continuous Loss-in-weight Blender Control System Menu Structure
Hopper Setup
“Inventory” page
¾
Hopper size
“Recipe” Page
(Start)
¾
¾
Clear Inventory
“Next” returns to “Recipe”
page
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
Extruder RPM is displayed
Extruder throughput is displayed
Blender throughput is displayed
Blender percentages are displayed
Hopper weights are displayed
Steady flags are displayed
Access “Recipes”
Access “Recipe Book”
Access “Clean out”
Access “Inventory” Page
Access “Setup” Page
“Next” to access “Inventory” page.
Calibration
¾
¾
Scale Calibration
Feeder Calibration
Clean out
¾
Run feeders manually
Panel View Config
¾
¾
Panel view GH version
PLC GH version
“Recipe Book” Page
¾
Save the running recipe to
the book
Password
¾
Delete a stored recipe
Load a stored recipe
Erase all stored recipes
Modify the product ID for a
stored recipe
¾
¾
New Password
Verify Password
¾
¾
¾
Return to the “Recipe” page
Units
¾
English or Metric
FIFO
¾
¾
Mass Flow FIFO Data
Feeder FIFO Data
Alarm Log
View, print, and clear the alarm
log
¾
Alarm Setup
¾
¾
¾
¾
¾
¾
¾
¾
No Material Flow
Re-fill to Long
No Material
Load cell Failure
Load cell over max.
Extruder Flow Alarm
Blender cannot keep up
Pop ups enabled
“Setup” Page
¾
Touch the ACS icon and enter in
the “user password”
Network Info
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Setting a Recipe
- To set a recipe, touch the hopper you want to change, a keypad will pop up, enter
the desired percentage for the hopper.
Clean Out
-Touching the “Clean Out” button will take you to the page to manually run the motors.
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Chapter 5: Maintenance
5-1 Preventative Maintenance Schedule
The mechanical design of the blender is simple and little maintenance is required. The only
moving parts are the re-fill valves, optional regrind agitators, metering augers, and optional
discharge slide gates. The checklist below contains a list of items which should be inspected
and/or replaced to keep your blender operating at peak efficiency. Perform each inspection at
the regular intervals listed below.
Figure 52: Sample Preventative Maintenance Schedule
System model #
Serial #
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
Daily
By
By
By
By
By
By
By
By
By
By
By
By
By
Inspect all hoppers
for any loose parts
- tighten them
immediately.
Verify quality of
compressed air
supply.
Inspect all weigh
hoppers for
obstructions.
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
By By By By By By By By By By By By By
Every week
Verify the blender
is properly
calibrated.
Check to make
sure that all hose
connections are air
tight.
Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Inspect air regulator
and air safety
circuits, if equipped.
Recalibrate If
necessary.
Photocopy this page for your maintenance records
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Maintenance
Note: Other service problems or questions can be answered by contacting the
Service Department.
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53
Maintenance
Chapter 6: Appendix
6-1 Spare Parts
Typical Blender Parts List
#
1
DESCRIPTION
015
08223-1
N/A
060
08278A
N/A
100
08412-1
A0770325
Lid (0.2 to 1.6 cu. ft. vacuum receivers)
Lid (3.0 and 6.0 cu. ft. vacuum receivers)
1/8” NPT fitting
1/4” NPT fitting
Bulkhead
35085K and 35086K
35154 and 35155
35146
2
3
4
5
Brass elbow
35118
24V DC Solenoid
33128
6
Dump cone
Air cylinder
15370
33126
15237
7
8
33073
33011G
Typical Weigh Hopper Assembly Parts List
7 kgs.
10 kgs.
15 kgs.
724.00832.00
30 kgs.
150 kgs.
Load
cells
724.00835.00
724.00836.00
724.00839.00
61-1250-150KG
Figure 64: Typical Allen-Bradley Controller Main Parts List
#
1
2
3
4
5
6
7
8
Description
Allen-Bradley SLC 500, CPU
24 VDC power supply
ALL MODELS
A0555198
A0563932
739.00027.00
A0565889
A0542207
A0563939
700.00278.00
715.01034.02
12 VDC power supply
Alarm light - Yellow strobe 24 VDC
Glass fuse – 3.0 amp (115 volt)
Ethernet module (optional)
Ethernet module cable
120 volt light bulb (power switch)
Figure 65: Typical Allen-Bradley Display Main Parts List
#
1
2
3
Description
Allen-Bradley PanelView Display ONLY
All MODELS
A0563571
Allen-Bradley PanelView flash memory card
PanelView 600 display – Connection cable
CONSULT FACTORY
A0565856
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Appendix
Annex B Information
The following design information is provided for your reference:
1. No modifications are allowed to this equipment that could alter the CE compliance
2. Ambient temperature:
3. Humidity range:
4. Altitude:
40 degrees Celsius (104 degrees Fahrenheit) – Maximum
50% relative humidity
Sea level
5. Environment:
6. Radiation:
Clean, dust-free and non-explosive
None
7. Vibration:
Minimal, i.e. machine mounting
8. Special installation requirements: Clean, dry compressed air 1 cfm @ 60 psi
(1.7 m³/hr @ 4.14 bar)
9. Allowable voltage fluctuation:
10. Allowable frequency fluctuation: Continuous
Intermittent
+/- 10%
+/- 1%
+/- 2%
11. Nominal supply voltage:
12. Earth ground type:
120/1/60 or 220/1/50 or 60 (Verify on serial number tag)
TN (system has one point directly earthed through a
protective conductor)
13. Power supply should include a neutral power connection.
14. Over-current protection is supplied in the blender control panel, but additional
protection should be supplied by the user.
15. The plug on the power cord serves as the electrical disconnect device.
16. Unit is equipped with three-phase motors (driven by single phase motor drive cards).
17. Functional identification
18. Cable support may be required for power cord, depending on final installation.
19. No one is required to be in the interior of the electrical enclosure during the normal
operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.
20. Doors can be opened with a screwdriver, but no keys are required.
21. Two-hand control is not required, or provided.
22. All hoppers should be moved around and set in place with a lift truck or equivalent.
23. There are no frequent repetitive cycles that require manual control⎯repetitive
functions are automatic while the blender is operating.
24. An inspection report detailing the functional test is included with the OL blender.
25. The machine is not equipped with cableless controls.
26. Color-coded (harmonized) power cord is sufficient for proper installation.
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Appendix
6-2 Addendum (Service Supervisor Information)
Note: Personnel not extremely familiar with this blender controller should
not use this section of the manual, or program can be compromised!
Note: Hidden, programmable features and hidden menu pages should not
be made available to floor operators. These pages also include the
Service Supervisor Information addendum located in this section.
Unauthorized changes to these factory settings by inexperienced
operators may prevent the unit from operating properly, and may
void part or all of the warranty.
Caution!
After all selections are made: Keep pressing the “Done” key until the unit
returns to the Recipe menu.
Note: Inexperienced operators or plant personnel should not access
programmable features. Unauthorized changes may prevent the blender
from operating properly and may void part or all of the warranty.
Note: Call the Service Department for assistance or for further explanation of
these or any other programmable features, which may or may not be
shown in this manual.
Note: Information included in this manual is subject to change without notice.
Passwords
• User Password
• Maintenance Password
“5413”
“3145348”
Caution!
Maintenance password should only be supplied to qualified personnel! The
program can be compromised.
Programmable Settings
The Blender software program has been designed to allow some customizing to achieve certain
desired operating parameters. The following is a listing of the selections that are “field”
programmable, followed by the procedure for doing so.
Pressing the manufacturer’s icon when in the “Setup” Directory Screen menu accesses this
menu.
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Appendix
Once you access the Engineering Menu you will see the following.
This is where you make adjustments to fine tune the blender’s performance. You will need to
assess the FIFO page previously mentioned in the manually to decide what changes need to be
made.
The following pages will show you the setup parameters and how to adjust them.
Advanced Hopper Options
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Appendix
Feed Factor Filter
This filter allows you to set the number of snapshots that the FIFO page looks at to find the
average deviation. Making this number bigger will cause the feeder to make changes slowly,
and decreasing the number will make changes faster. You may want to make this number
smaller on a feeder with a low feed rate.
Steady Feed Factor
This is the parameter that sets the percent deviation allowed for the feeder to give a stable flag.
The lower the percentage the more accurate the feed. With hard to feed materials or materials
that vary in bulk density you may have to increase this number. Also if a lot of vibration is
occurring that cannot be resolved you may have to increase this.
Max WTP/RPM
This is the maximum weight through put per RPM allowed. This is settable in case you have a
very large auger that you are trying to run at a low feed rate. This will help to keep the auger
from making rapid adjustments.
Re-fill Percentage
This is the level the hopper will go down to before re-filling.
Learn Percentage
This is the size of the snapshot previously mentioned. Increasing this gives you better stability
with materials that very in bulk density or do not flow consistently. Decreasing this gives you
faster updates on the FIFO page for materials that are relatively uniform.
Summary
When adjusting the above parameters you will want to look at the FIFO page and analyze the
information given. You should be able to determine from the percent deviation what changes
to make. For example if an additive takes a long time to give a steady flag you may want to
lower the Feed Factor Filter or Lower the learn percentage. When making changes do make
them one at a time and observe the FIFO page for results. Another common example is you are
running regrind through a feeder and your not getting a steady flag because your percent
deviation is too high. You may want to increase the Steady Feed Factor or you could increase
the Learn Percentage. A larger Learn Percentage is usually more stable than a small
percentage.
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Appendix
Advance PID Options (mass flow setup)
Sample Time once in Steady Window for FIFO
This is how often the control takes snap shots of the mass flow hopper and enters the number in
the FIFO table. For quicker FIFO updates you would decrease this number. For a more stable
process you would increase this number.
Steady System Limit
This is the allowable percent deviation around the median. The median will be half way
between the re-fill set point and the hopper size set point. For material that varies in bulk
density or does not flow consistently you may have to increase the limit.
Steady System Time Test
This timer is used to determine whether or not to show the Steady System flag on the main
control screen. Rather than going in and out of stable, the process must remain stable for the
set time and then the Steady System will be shown.
PID Timer
This is the amount of time that the blender will run without making a change to the auger
speeds to adjust the blender though put i.e. pounds per hour.
PID Gain
The gain increase or decreases the size and speed of the adjustments made to the PID. A
smaller number makes slower adjustments. A bigger number makes faster adjustments.
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Appendix
PID Integral Constant
Works the same as the Gain.
Feeder Speed Limits
This allows you to set the minimum and maximum speed for the motor drives as a percentage.
The drives are not supposed to be run at less than 8 hertz and should not be run above 115
hertz.
Extruder RPM Options
This gives you the option of having no extruder speed input, writing the extruder speed to the
blender through the Ethernet, or using a proximity sensor on the end of the extruder screw.
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Appendix
Allowed Extruder RPM Change for Steady Flag
This is how much the extruder RPM can vary and still be considered steady. With no extruder
measurement the control always assumes a steady RPM.
Update Time for Prox Method in seconds
This is how often the extruder speed updates from the prox.
Extrusion Control Options
Feeder Setup
This screen allows you to enter the maximum auger speed in Hertz.
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Appendix
Advanced Alarm Options
This alarm is for no material flow through a auger, this could be caused by a blockage stopped
motor etc.
No Flow Timer
This is the amount of time used to measure the bit flow (weight loss) through a hopper, to
determine if an alarm is warranted.
No Flow Bits
This is the amount of weight loss in a set amount of time (No Flow Timer) to sound an alarm.
Please contact the ACS Service Department with any other questions.
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Appendix
6-3
Technical Assistance
Parts Department
Call toll-free 7 am–5 pm CST
800.423.3183 or call 262.641.8610
Fax 262.641.8653
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial number
of your unit when you contact us. A customer replacement parts list is included in this manual for your
convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent
customer service.
Service Department
Call toll-free 8 am–5 pm CST 800.423.3183 or call 262.641.8610
Emergencies after 5 pm CST, call 847.439.5655
We have a qualified Service Department ready to help. Service contracts are also available for most of our
Sales Department
262.641.8610
Call
Monday–Friday, 8 am–5 pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contracting Department
262.641.8610
Call
Monday–Friday, 8 am–5 pm CST
Let us install your system. The Contracting Department offers any or all of these services: project
planning; system packages including drawings; equipment, labor, and construction materials; and union or
non-union installations
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Appendix
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