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Sterling Allen-Bradley 015 Instruction Manual

Continuous loss-in-weight blenders
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________________________________
Continuous Loss-in-Weight Blenders
Allen-Bradley SLC 5/04 Programmable Controller
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.
PanelView 600 Touch Screen Interface
Part Number: 882.092698.00
Bulletin Number: BF3-615
Effective: 9/1/08
with
and
_________________________
_________________________
_________________________

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  • Page 1 ________________________________ Continuous Loss-in-Weight Blenders Allen-Bradley SLC 5/04 Programmable Controller PanelView 600 Touch Screen Interface 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.

  • Page 2: Shipping Information

    Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY ... 6 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 CHAPTER 2: FUNCTIONAL DESCRIPTION...
  • Page 5 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...

  • Page 6: Chapter 1: Safety

    Chapter 1: Safety 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.
  • Page 7 Continuous Loss-in-Weight Blender Safety Tags Description Pinch Point - Slide Gate Shear Point - Rotating Mixer or Agitator High Voltage Inside Enclosure Shear Hazard - Rotating Auger Continuous Loss-in-Weight Blenders Description Read Operation & Installation Manual Earth Ground Protected Earth Ground Lifting Point Chapter 1: Safety...

  • Page 8: Warnings And Precautions

    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.

  • Page 9: Responsibility

    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.

  • Page 10: Operator Responsibility

    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.

  • Page 11: Maintenance Responsibility

    • 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.

  • Page 12: Chapter 2: Functional Description

    Chapter 2: Functional Description 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 Blending Capability Maximum blending rate in lbs./hr (kgs./hr)

  • Page 13: Typical Features & Components

    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. •...

  • Page 14: Blender System Component Description

    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 •...
  • Page 15 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.
  • Page 16 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.
  • Page 17 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).
  • Page 18 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.

  • Page 19: Options

    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).

  • Page 20: Safety Devices And Interlocks

    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.
  • Page 21 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.

  • Page 22: Chapter 3: Installation

    Chapter 3: Installation 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.

  • Page 23: Site Requirements

    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.
  • Page 24 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.
  • Page 25 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”...

  • Page 26: Electrical Installation

    Figure 8: Typical Layout for a floor mounted blender 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.

  • Page 27: Pneumatic Installation

    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 &...

  • Page 28: Overall Installation (Summary)

    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.

  • Page 29: Set-Up

    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).

  • Page 30: Final Connections

    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.

  • Page 31: Controller Setup

    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.
  • Page 32 will suffice. The weight will be in pounds, unless the blender is provided for metric display operation (kilograms). Given the two weight points on the load cell scale, the controller will be able to determine any other weight on the load cell span. This is limited to the maximum capacity of the load cell. The standard load cell used on these blenders have a span accuracy of 1/10 The maximum capacity of each load cell is clearly marked on the fixed top of the load cell.
  • Page 33 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. Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 34 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.
  • Page 35 Touch the “ACS Group” Logo. Then enter password “5413”. Touch the “OK” button. Touch the “Calibration” button. Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 36 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.
  • Page 37 Figure 12: Hopper Sizes Hopper Diameter 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”...
  • Page 38 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”) Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 39 To change a password proceed as follows: Touch the “ACS Group” logo. Enter password and touch “OK”. Touch “User Password” Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 40 -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.
  • Page 41 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”. Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 42 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”...
  • Page 43 Setting Blender for English or Metric Touch the “ACS Group” logo. Enter the password and touch “OK”. Touch “Units”. Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 44 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”...
  • Page 45 Enter the Password and touch “OK” Touch “FIFO Diagnostics” Select “Mass Flow FIFO Data” or “Feeder FIFO Data” Continuous Loss-in-Weight Blenders Chapter 3: Installation...
  • Page 46 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.

  • Page 47: Chapter 4: Operation

    Chapter 4: Operation 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: •...
  • Page 48 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.

  • Page 49: Controller Description & Operation

    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.
  • Page 50 Figure 15: Blender Menu Structure (Standard Unit) Continuous Loss-in-weight Blender Control System Menu Structure “Recipe” Page (Start) 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”...

  • Page 51: Setting A Recipe

    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. Continuous Loss-in-Weight Blenders Chapter 4: Operation...

  • Page 52: Maintenance

    Chapter 5: Maintenance 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.
  • Page 53 Note: Other service problems or questions can be answered by contacting the Service Department. Continuous Loss-in-Weight Blenders Chapter 5: Maintenance...

  • Page 54: Appendix

    Chapter 6: Spare Parts Typical Blender Parts List DESCRIPTION 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 Brass elbow 24V DC Solenoid Dump cone Air cylinder Typical Weigh Hopper Assembly Parts List 7 kgs.

  • Page 55: Annex B Information

    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: 5. Environment: 6. Radiation: 7. Vibration: 8.

  • Page 56: Addendum (Service Supervisor Information)

    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.
  • Page 57 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.
  • Page 58 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.
  • Page 59 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.
  • Page 60 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.
  • Page 61 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.
  • Page 62 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.

  • Page 63: Technical Assistance

    Technical Assistance Parts Department Call toll-free 7 am–5 pm CST 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.

This manual is also suitable for:

Allen-bradley 060Panelview 600Allen-bradley 100Allen-bradley slc 5/04

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