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Sterling A0567659 Operation And Installation Manual

Gravimetric bath blenders with mitsubishi controller
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  • Page 2 ________________ ________________ ________________ ________________ ________________ ________________ Sterling is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. © Copyright Sterling 2003 All rights reserved. Revision: NEW Part No. A0567659 Bulletin No.
  • Page 3 Please note that our address and phone information has changed. Please reference this page for updated contact information. These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon.
  • Page 4 Please note that our address and phone information has changed. Please reference this page for updated contact information. These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon.

  • Page 5: Table Of Contents

    Table of Contents Table of Contents..................3 Safety Considerations ..................5 Annex B Information ................7 General Information................8 Introduction ..................8 Equipment Function ............... 8 1-3 Accessories ..................8 1-4 Customer Service................8 1-5 Necessary Documents ..............9 1-6 System Capabilities................. 9 1-7 Equipment Covered by this Manual..........
  • Page 6 Table of Contents Operation ...................47 SGB Blender Sequence of Operation .......... 47 Quick Start Procedure..............47 Recipe Entry Formats..............48 SGB Series Control System Menu Structure........ 51 Blender Calibration............... 52 Controller Mode Setup ..............54 Color Change ................56 Additional Operation Features ............. 58 Stroke Limiters for Metering Gates..........

  • Page 7: Safety Considerations

    Safety Considerations Sterling equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: Follow all SAFETY CODES.
  • Page 8 Sterling “SGB-E” Series Blenders This blender is manufactured by ACS, Inc. at the ACS-Wood Dale facility: ACS, Inc. 801 AEC Drive Wood Dale, IL 60191 Phone: 630.595.1060 Fax: 630.595.6641 The equipment is distributed in Europe by our European facility: ACS-EUROPE...

  • Page 9: 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: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity 4.

  • Page 10: General Information

    General Information 1-1 Introduction We are pleased to supply Sterling auxiliary equipment for your facility. We manufacture a complete line of auxiliary equipment to satisfy all of your material handling, process cooling, scrap reclaim, size reduction, and automation requirements. Please feel free to contact your sales representative or our office if you have any questions.

  • Page 11: Necessary Documents

    The documents listed below are necessary for proper installation, operation and maintenance of SGB Series Gravimetric Batch Blenders. You can obtain additional copies from the Service Department at Sterling or ACS Europe. Make sure that appropriate personnel get familiar with these documents: •...

  • Page 12: Sgb" Series Weigh Blender Mechanical Features

    1-8 “SGB” Series Weigh Blender Mechanical Features SGB Slide Gate Blender ® Efficient Opti-Mixer and “HC” mixer designs promote homogeneity • Exclusive diamond design slide gate metering assemblies meter a large range for • free flowing pellet materials Slide gate stroke limiting restrictors provided for accurate metering of minor •...

  • Page 13: Sgb" Series Weigh Blender With Mitsubishi Touch-Screen Control Features

    1-9 “SGB” Series Weigh Blender with Mitsubishi Touch- Screen Control Features • LCD touch-screen interface display operator control panel with 8’ cable • Target vs. actual set point verification • Inventory accumulation for all ingredients • Audible and visual alarms •...

  • Page 14: Sgb (-E) Series Specifications

    1-10 SGB (-E) Series Specifications SGB Series Specifications SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 Number of materials blended 2 to 6 2 to 5 Slide gate (adjustable, in (mm)) square 2 (50) 2.5 (63) 3 (76) 4 (101) Supply hopper capacity, ft³ (l) 0.75 (21) 1 (28) 1.5 (42)

  • Page 15: Model Sgb Blender System Component Description

    1-11 Model SGB Blender System Component Description This section describes the various components of the blending system. The SGB blending system is made up of the following components: 1-11-1 Material Supply Hoppers 1-11-2 Slide Gate Metering Assemblies 1-11-3 Weigh Hopper 1-11-4 Weigh Hopper Dump Valve 1-11-5 Mix Chamber 1-11-6 Operator Control Panel...

  • Page 16: Material Supply Hoppers

    1-11-1 Material Supply Hoppers The material supply hoppers are located on top of the blender frame. These hoppers store a supply of material for the individual metering devices. They are sized based on the total throughput of the blender. The SGB blending system does not include any level indication devices on the unit.

  • Page 17: Slide Gate Metering Assemblies

    The air cylinders operating the slide gate are rugged, stainless steel cylinders designed for industrial use. DIAMOND GATE OPEN The unique Sterling diamond gate provides a constant aspect opening that remains square regardless of the stroke length of the cylinder. This design provides a wider...
  • Page 18 Each of the diamond gate air cylinders is actuated by a solenoid valve, which are controlled by the blender. When the solenoid valve is energized, it opens the metering valve cylinder. When the solenoid valve is de-energized, it closes the metering valve cylinder.

  • Page 19: Weigh Hopper

    1-11-3 Weigh Hopper The weigh hopper on the SGB blender is used to weigh each batch of material, and includes an air-operated discharge valve. After the batch is weighed and the level sensor in the lower mix section is uncovered, the valve will open and discharge the batch into the mixer with the existing blended material.
  • Page 20 1-11-4 Weigh Hopper Discharge Valve The weigh hopper discharge valve holds the material until it is dumped into the mixing section. The cylinder is actuated by a solenoid in the valve stack on the rear of the blender. In looking at the pneumatic circuit, you can see that the air regulator controls the flow of air to the valve stack.

  • Page 21: Mix Chamber

    1-11-5 Mix Chamber All of the Sterling batch blenders are equipped with an integral mix chamber. The mix chamber holds multiple batches of material so any variations in a batch are averaged over time. 1-11-5-1 Opti-Mixer™ The Opti-mixer™ is designed to provide bi-directional mixing action and can be easily taken apart for cleaning.
  • Page 22 Typical Setup Screens Page 20 of 118 SGB Batch Blender with Mitsubishi Controller...
  • Page 23 Typical Operator Screens SGB Batch Blender with Mitsubishi Controller Page 21 of 118...
  • Page 24 Note: The touch-screen panel display on your unit may be slightly different than shown. Page 22 of 118 SGB Batch Blender with Mitsubishi Controller...

  • Page 25: Pneumatic Slide Gate Below Mixer (Optional)

    1-12 Pneumatic Slide Gate Below Mixer (Optional) The SGB blending system can be equipped with an optional pneumatic slide gate below the mixing chamber. The gate is used in applications when the blender is mounted above a large hopper, or for gaylord filling, etc. This gate holds the material in the mixing section, to ensure that it is properly mixed.

  • Page 26: Safety

    Read and follow the instructions in this manual before installing, operating, or maintaining any equipment. Additional copies are available from Sterling. Only qualified persons should work on, or with, this equipment. Work only with approved tools and devices.

  • Page 27: Tools And Equipment Needed

    2-2 Tools and Equipment Needed You’ll need the following: • Hand tools • Fork lift or overhead lift • Wire, conduit, and fittings for wiring runs (if receptacle is not already in place) • Mounting bolts with nuts and washers •...

  • Page 28: General Responsibility

    REPORTING A SAFETY DEFECT NOTE: If you believe that your equipment has a defect which could cause injury, you should immediately discontinue its use and inform Sterling, at our address listed in this manual. The principle factors which can result in injury are: Failure to follow proper operating and clean-out procedures, i.e.

  • Page 29: Operator Responsibility

    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.

  • Page 30: Maintenance Responsibility

    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.

  • Page 31: Safety

    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 on your blender, use it. The work platform should have secure footing and a place for tools and parts.

  • Page 32: Safety Circuit Standards

    2-8-4 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. The safety devices that are utilized on Sterling SGB models are primarily concerned with the pneumatics and electrical power disconnection, and the disabling of moving parts that may need to be accessed during the...
  • Page 33 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.

  • Page 34: Electric Safety Interlock Switch (All Models)

    Interlock Switch Electrical Disconnect Plug 2-9 Electric Safety Interlock Switch (All Models) A unique electric safety switch is used to shut off power to the blender any time the mixer door is opened. Do not tamper or alter with this switch in any way. Page 32 of 118 SGB Batch Blender with Mitsubishi Controller...

  • Page 35: Shipping Information

    Shipping Information 3-1 Unpacking and Inspection You should inspect your Sterling batch blender components for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary.

  • Page 36: In The Event Of Shipping Damages

    Notify the transportation company’s local agent if you discover damage. Hold the damaged goods and packing material for the examining agent’s inspection. Do not return any goods to Sterling before the transportation company inspection and authorization. File a claim against the transportation company. Substantiate the claim by referring to the agent’s report.

  • Page 37: If The Shipment Is Not Complete

    Parcel Post Shipment Notify Sterling at once in writing, giving details of the loss or damage. This information is required for filing a claim with our insurance company. Hold the damaged goods with the container and packing materials for possible inspection by postal authorities.

  • Page 38: If The Shipment Is Not Correct

    3-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact Sterling immediately. For shipments in the United States and Canada, call 1 (800) 233-4819; for all other countries, call our international desk at 001 (630) 475-7491.

  • Page 39: Installation & Setup

    While in operation, the SGB applies horizontal and vertical pressures to the mounting flange. If there is a question as to the mechanical stability of a mounting flange, contact Sterling’s Engineering department. SGB Batch Blender with Mitsubishi Controller Page 37 of 118...
  • Page 40 Verify all clearances on the top and beside the processing machine. This is to insure that all motors, hoppers, control panels, etc. have adequate room for proper operation and servicing. Refer to the assembly drawing with the unit for actual height and width dimensions.

  • Page 41: Mezzanine Mount

    If there is a question as to the mechanical stability of a mounting flange, contact Sterling’s Mechanical Engineering department. Ensure that the gravity feed tube is installed in a vertical position, so that the materials will gravity flow to the extruder hopper.
  • Page 42 SGB in place. Important! The blender must be securely fastened to the floor before operating. Sterling assumes no responsibility for any damages resulting from improper installation or improper handling during installation. Make sure that the blender is securely mounted to the floor before installing loading equipment, loading with material and starting.

  • Page 43: Installation Overview

    4-3 Installation Overview This section will familiarize the reader with commonly used procedures for blender installation. After reading this chapter, the reader will be familiar with the installation requirements for all SGB blenders. 4-4 Mechanical Installation The installation procedure should be used as a general guideline for the proper installation steps required to install the SGB blending system.

  • Page 44: Electrical Installation

    4-5 Electrical Installation The standard Sterling SGB blending system is designed to operate on 120/1/60 supply voltage (220/1/50 CE models are also available). The current requirements vary with the blender’s size and throughput rating. For exact current requirements, check the blender serial number tag, located on the rear plate of the mixer section.

  • Page 45: Pneumatic Installation

    CUSTOMER-SUPPLIED COMPRESSED AIR COMPONENTS OS/OA BLENDER Sterling provides all pneumatic lines on the blender piped to a single ¼” NPT standard pipe thread fitting. The SGB blending system requires approximately 1 cfm (1.7 m³/hr) @ 60 psi (4.14 bar) maximum air pressure for proper operation.

  • Page 46: Weigh Hopper Installation

    SGB blending system. 4-7-2 Weigh Hopper Installation Remove the weigh hopper from the shipping box and install it in the blender on the load cell brackets. Connect the airline and close the mixer door, securing the latch. 4-7-3 Load Cell Adjustment The mechanical setup of the SGB blending system involves the adjustment of the weigh hopper load cells (Please refer to the figure on the next page).
  • Page 47 4-7-4 Final Setup Connect the blender to the appropriate power source Connect the compressed air piping, ensuring that a 5-micron air filter is installed, along with the proper water trap, and lubrication unit, if required. Verify that 60 psi (4.14 bar) of clean, dry compressed air is supplied to the blender.
  • Page 48 The screen shown below allows the operator to control the blender. The blender can be started or stopped and the recipe values can be changed. Other data shown on this screen consists of the mixer status, recipe status, and feeder type data. The Recipe Screen should startup in the “Quick Set”...

  • Page 49: Operation

    Operation 5-1 SGB Blender Sequence of Operation 1. Blender is started by turning system on or material dropping below level switch in mix chamber. 2. Metering gates are opened to meter material into the weigh hopper in the programmed order. 3.

  • Page 50: Recipe Entry Formats

    The Recipe Format screen allows the user to change many parameters concerning the way that the recipe is entered by the operator. It is accessed by touching the Sterling icon on either the Recipe screen or the Inventory Screen. The user must enter in the User Password to gain access (see User Password Setup for details.).
  • Page 51 the blender and the operator is not required to enter it. The ingredient names selected will be displayed on the run mode display so the operator will know what material is being blended. Important! The #1 hopper (“NAT” - Virgin Material) recipe ingredient will not be shown on the recipe setup menu.
  • Page 52 The preset part will be divided by the total of all parts, with each part representing the calculated weight for ratio control. Example of a 5-component Blend in “Parts” Mode Calculated Weight Feeder Tag Preset Part (Ratio Control) Virgin 7,200 7,200/10,000 Regrind 2,000...

  • Page 53: Sgb Series Control System Menu Structure

    “Setup” Page “Alarm Silence” delay Login by going to Inventory page, touch “Login”, then enter your User Interface Lock password. Touch the Sterling Lock the user interface to logo to access setup. prevent others from making changes or viewing your blender, be sure to logout after locking.

  • Page 54: Blender Calibration

    (Recommended only if the calibration is out of spec) 1. Login by touching “login” from the Inventory Page and enter “5413”, then touch the Sterling logo to access setup. 2. Touch “Calibration” and then “Scale Calibration”. 3. Remove the weigh hopper, clean it out and press “OK”.
  • Page 55 time the mixer will mix or the batch is dumped. Enter a “Mixing Time” by pressing the number next to “sec”, this is the amount of time to run the mixer after a batch is dumped into the mixing chamber. Remember that if the mix time is too long you may get material separation.

  • Page 56: Controller Mode Setup

    5-5-4 Verifying Calibration (Recommended on a periodic basis to ensure accuracy) Login by touching “login” from the Inventory Page and enter “5413”, then touch the Sterling logo to access setup. Touch “Calibration” and then “Direct Scale Readout”. Remove the weigh hopper.
  • Page 57 Inventory Shutdown: This feature allows the blender to make a certain amount of material at a time. If this feature is set to “0” then the feature will be disabled. If this option is used, the blender will make the set amount of material and will then shutdown and wait for the operator to restart the blender.

  • Page 58: Color Change

    **Note: The blender monitors the operator’s entries and determines if the recipe is valid before accepting the new recipe. If there is an error (such as the recipe does not add up to 100% and the blender is in Percentage Mode.) then a message is shown on the Recipe screen to alert the operator of the problem.
  • Page 59 Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air) sources prior to servicing or cleaning any Sterling product, including all SGB Series blending systems. Failure to do so may result in serious injury or death. SGB Batch Blender with Mitsubishi Controller...

  • Page 60: Additional Operation Features

    5-8 Additional Operation Features 5-8-1 Display Description (LCD) The SGB blending system utilizes a standardized menu format. Each screen was designed to be user-friendly and provide the operator with the necessary information to run the blender. A typical menu is shown in the figure above. This display, which is defaulted to when the controller is turned on, provides the operator with the following information and options: •...
  • Page 61 5-8-2 Weigh Hopper (Load Cell) Calibration on blenders equipped with an OptiMix mixer Enter the Setup menu as described previously. See Section 5-3 for menu tree. The factory pre-calibrates the weigh hopper on the SGB blenders. Button #3 on the Setup Menu is “Calibration”. Press it to enter the screen (shown below) which will prompt you to enter the Calibration area.

  • Page 62: Mix Timer

    5-8-3 Mix Timer The mix timer is the amount of time that the mix motor will mix the material after it has entered the mixing section of the SGB blender. The timer has a range of 1 to 999 seconds. To set the value of the mix timer, the user must gain access to the Setup Menu.

  • Page 63: Mixer Options

    mix cycle after each dump of the weigh hopper. To view and change the value of the re-mix timer, refer to the “Mixer and Dump Setup” menu. All current values for Mixing and Remixing Times will be shown on this screen. The re-mix timer default value is factory preset at zero.

  • Page 64: Weigh Hopper Dump Cycle

    To enter the dump cycle menu, first enter the Setup menu by pressing the “Sterling” icon from the main menu. Enter the password and press enter. Next, press the button marked “Mixer and Dump Setup”. The display will show the “Mixer and Dump Setup”...
  • Page 65 3.) Select a feeder (1-6) by touching the “Select Feeder” box. 4.) The current settings for the hopper that you have chosen will now be shown on the screen. 5.) Make the necessary adjustments to the “Stop/Continue if “Out of Material,”...
  • Page 66 Calibration Error, Clean out hopper and check calibration: This • alarm indicates that the maximum empty weight for the weigh hopper has been exceeded. The blender will automatically tare up to 0.25 lbs of material, but if this weight is exceeded, then an alarm will appear.

  • Page 67: General Operation

    • E-Stop Screen: The blender is equipped with an E-stop switch that removes the power from all mechanical outputs. The E-Stop Screen appears along with an audible alarm whenever the E-Stop is activated. The operator can not access any screens until E-Stop is deactivated.
  • Page 68 This screen will allow you to Open or Close the Feeder, Weigh Hopper, Mixer Knife Gate, Empty the Entire Blender, Start or Stop the Mixer Motor, Test the Alarm Output, Find out the Mixer Proximity Status and monitor the Current Hopper Weight. Warning Empty Entire Message...

  • Page 69: Standard Run Time Displays

    the mixer section of the blender. If the dump delay is set, the mixer will start before the weigh hopper dump will open for the selected time. The blender will sit at rest until the high-level sensor in the mixing chamber is uncovered to start another weigh cycle.
  • Page 70 Average Batch Time Blender Inventory Maximum Rate Totals Go to Recipe Page Clear the inventory totals Accumulated Material Number of Batches Usage Rate This display indicates the amount of material in pounds that has been used by each feeder of the recipe. It is important to note that the weights are rounded off to the closest pound.
  • Page 71 • Recipe Book Page • Recipe Format Upon Start Up, the blender controller will default to the “Recipe Menu” screen. The “Recipe Book” screen can be accessed in the “Recipe Page” and is useful in storing and retrieving recipes. The Recipe format option can be accessed in the Setup screen and is used to select one of three available formats: “Quick Set”, Percentage Mode or Parts Mode.
  • Page 72 can be scrolled to read “NAT” (natural), “RGD” (regrind), or “ADD” (additive). The selected label will be displayed for the ingredient hopper with an arrow next to the abbreviation. Component #3 is designed to handle regrind and most models come equipped with a larger, square gate to reduce the likelihood of bridging.
  • Page 73 Example calculations of a five (5) -component blend in “Quick Set” Virgin (NAT): Additive1 (ADD): 5.00% - of virgin component Regrind (RGD): 30.00% - of total batch Additive2 (ADD): 2.00% - of virgin component Additive3 (ADD): 1.00% - of virgin component Batch Size: 10.00 lbs.
  • Page 74 40,000-lb. run of a certain specification plastic extrusion. Others may wish to fill a 1,000-lb. gaylord box in a central blending application. In either case, Sterling has provided a means to automatically stop the blending system when the blended material has reached a preset total blended weight.
  • Page 75 In many applications, it is favorable to hold several recipes in the memory of the blending system. The SGB has provided for this by incorporating Sterling’s recipe book software. The recipe book is capable of holding 50 different recipes. These may be stored and recalled by number.
  • Page 76 Always verify that the Current Recipe is showing what you want to run, and that the correct recipe has been downloaded from the book. The recipe book section contains the following Items: • Save Running Recipe to the Book • Load a Stored Recipe from the Book •...
  • Page 77 5-8-19-2 Load a Saved Recipe from the Book The load from book function allows the operator to retrieve a previously stored recipe from the recipe book and install it into the current recipe menu. This will overwrite the current recipe, so make sure that it has been saved to the book before installing a new recipe in its place.

  • Page 78: Controller Features

    5-8-20 Controller Features 5-8-20-1 Display Time and Date The display Time and Date item in the upper right corner of the “F940 Config” menu is used to verify the current time and date information. 5-8-20-2 Setting Date & Time The Set Date & Time feature is located in the “Panel View Config”...

  • Page 79: Stroke Limiters For Metering Gates

    5-9 Stroke Limiters for Metering Gates Stroke limiters are supplied on components 1 through 4 with all SGB blenders to allow standard metering gates to meter small amounts of low percentage additive materials. Generally, the stroke limiter (Item 30) is not required on major ingredients (usually number 1 and 3) and should be removed.

  • Page 80: Maintenance

    Disconnect and lock out main power before servicing electrical equipment. 6-2 Maintaining Blenders Sterling blenders need periodic maintenance to provide long dependable service. Check these elements regularly: • Check functionality of safety circuit daily. • Maintain proper air pressure and drain water from trap assembly on regulator –...

  • Page 81: Controller Setup

    6-3 Controller Setup This section describes the proper setup of the SGB 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 82: Sgb Series Blender Menu Structure

    Target vs. actual data units by hitting “Login” and entering (lbs. or kgs.) in your password. Then access setup by touching the Alarm Log Sterling Logo. View and clear the alarm log Alarm Setup “Stop/Continue” when out of material “Alarm/No Alarm” when out of material “Alarm Silence”...

  • Page 83: Mechanical

    6-5 Mechanical The mechanical design of the blender is very simple and very little maintenance is required. The only moving parts are the metering gates, weigh hopper dump valve and mixer agitator. The following maintenance is suggested: Daily • Inspect blender for any loose parts-tighten them immediately. •...

  • Page 84: Electrical

    6-6 Electrical 6-6-1 Description and Objectives This section is designed to give the operator an overview of the electrical system that controls the SGB blending system. Since the SGB’s control panel is a self-contained pluggable item, seldom will a maintenance person be required to enter the control panel.

  • Page 85: Output Signals From Programmable Controller

    6-6-4 Output Signals from Programmable Controller The SGB blending system uses several output control signals to control the process. All of these are very similar in nature, the first of which is the mixer motor control. The mixer motor is controlled by a PLC output. The weigh hopper dump valve output functions similar to the mix motor output.

  • Page 86: Pneumatic System Maintenance

    CUSTOMER-SUPPLIED COMPRESSED AIR COMPONENTS OS/OA BLENDER Sterling provides all pneumatic lines on the blender piped to a single ¼” NPT standard pipe thread fitting. The SGB blending system requires approximately 1 cfm @ 60 psi (1.7 m³/hr @ 4.14 bar) air pressure for proper operation.

  • Page 87: Troubleshooting

    Troubleshooting 7-1 Description and Objectives This section provides basic troubleshooting procedures to common SGB blending system problems. Any problem encountered that is not listed should be discussed with an Sterling service technician. Problem Possible solution Nothing happens when I Check to make sure that air is hooked up and the regulator gauge reads push “Start Blender”...
  • Page 88 Problem Possible solution Weigh hopper occasionally Check batch weight setting in the recipe menu. See the setup chapter for overfills. more information. Check the load cells and weigh hopper mounting for binding, etc. Check to see that a pellet has not lodged under a load cell. Check the ingredient supply hoppers to verify proper ventilation.
  • Page 89 Problem Possible solution Mixer won’t shut off and Check the Mixer and Dump Setup to see if the mixer is configured for runs continuously. “Continuous Mixing”. Set it to “Timed Mixing”. Check the value of the mixer timer setting. Check the value of the dump delay timer. Check the mixer motor fuse.
  • Page 90 Increase the Allowed Underfeed value under Feed Algorithm Options. Decrease the Retries before Double Gate Time. Other service problems or questions can be answered by contacting the Sterling Service Department. Page 88 of 118 SGB Batch Blender with Mitsubishi Controller...

  • Page 91: Blender Options

    Blender Options The following is a list of options, which your blender may have been equipped with: Regrind Auger Metering (RAM) Used for feeding difficult regrind materials. Low Level Sensors Detects material supply problems before blender runs out. Remote Touch Screen Interface Allows control of blender from a second location up to 50 feet (30 meters) away.

  • Page 92: Spare Parts

    Spare Parts 9-1 Spare Parts List SGB Series Gravimetric Batch Blending Systems Please see Section 9-2 for parts identification and exploded views. Model SGB-450 Part No. Description 53292 Air Cylinder (weigh hopper dump) 53272 2kg Load Cell 10220 Mixer Agitator (Opti-Mixer) A0556548 Mixer High Level Sensor 35448...

  • Page 93: Model Sgb Blender System Component Description

    A0565882 Calex Module A0569702 A0569708 SGB Graphics Panel A0542200 1.5 Amp Fuse A0542207 3.0 Amp Fuse A0569108 Calibration Weight (~25 lbs.) 9-2 Model SGB Blender System Component Description This section describes the various components of the blending system. The SGB blending system is made up of the following components: •...
  • Page 94 9-2-2 Typical Mixer Section (Front) Typical Opti-Mixer™ - Front Assembly Detail Page 92 of 118 SGB Batch Blender with Mitsubishi Controller...
  • Page 95 Nameplate and indicator mounting plate Nameplate Upper polycarbonate Opti-Mixer™ door Door clamp “Caution” label Lower stainless steel Opti-Mixer™ door Mixer agitator door bushing Door hinge Door hinge base 9-2-3 Typical Mixer Section (Rear) Typical Opti-Mixer™ - Rear Assembly Detail SGB Batch Blender with Mitsubishi Controller Page 93 of 118...
  • Page 96 Opti-Mixer™ back plate Cover plate Back control panel Cover plate Proximity sensor (Mixer “high” level) Mixer proximity sensor mounting plate Mixer gear motor Mixer agitator shaft coupling 9-2-4 Typical Mixer Frame Page 94 of 118 SGB Batch Blender with Mitsubishi Controller...
  • Page 97 Typical Opti-Mixer™ Frame Assembly Hinge mounting bracket Mixer door clamp Load cell cover Opti-Mixer™ top plate Opti-Mixer™ frame Warning label Opti-Mixer™ frame side panel Hinge mounting bracket SGB Batch Blender with Mitsubishi Controller Page 95 of 118...
  • Page 98 9-2-5 Typical Gate Assembly Typical SGB Series Diamond Gate Assembly Detail Slide gate guide rod Stainless steel gate assembly base Slide gate stop (stroke-limiter) Retaining clip Slide gate air cylinder Slide gate air cylinder pneumatic connector fitting Slide gate air cylinder pneumatic barb fitting Slide gate assembly material chute (deflector) Notice (warning) label Diamond v-gate (metering slide gate)
  • Page 99 Typical SGB-450 Series Hopper Assembly Detail Mild steel hopper cover Hopper insert (square to diamond-polyurethane) Mild steel hopper Gasketing Polycarbonate access door Polycarbonate hopper sight glass Blow-off tool holder Blow-off tool Drain plug Cleanout door clamp Optional low level proximity sensor mount 9-2-7 Typical Weigh Hopper SGB Batch Blender with Mitsubishi Controller Page 97 of 118...
  • Page 100 Typical Weigh Hopper & Load Cell Detail Left weigh hopper bracket Inside mixer plate Weigh Hopper Weigh hopper discharge air cylinder pneumatic connector Weigh hopper discharge air cylinder Weigh hopper discharge air cylinder mounting bracket Weigh hopper discharge hinge pin (bolt) Weigh hopper discharge flapper Right weigh hopper bracket Spacer...

  • Page 101: Technical Assistance

    Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 783-7835 or call [262] 641-8600, 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.

  • Page 102: Returned Material Policy

    After inspecting the material, a replacement or credit will be given, at Sterling’s discretion. If the item is found to be defective in materials or workmanship, and it was manufactured by Sterling, purchased components are covered under their specific warranty terms.

  • Page 103: Warranty

    10-3 Warranty Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the Company’s opinion, are defective.

  • Page 104: Safety Tag Information

    Safety Tag Information 11-1 SGB Blender Safety Tags Pinch Point Read Operation Slide Gate and Installation Manual Shear Point Earth Ground Rotating Mixer High Voltage Protected Earth Inside Enclosure Ground Shear Hazard Rotating Auger Lifting Point Page 102 of 118 SGB Batch Blender with Mitsubishi Controller...

  • Page 105: Pushbutton And Touchscreen Tags

    11-2 Pushbutton and Touchscreen Tags Button Function Turns power on to the blender controller. (Found on back of controller.) Power On Turns power off to the blender controller. (Found on back of controller.) Power Off Stops blender & re-starts controller. Press to move back one screen level in controller function.

  • Page 106: Blender Identification (Serial Number) Tag

    11-3 Blender Identification (Serial Number) Tag (Located on back of mixing chamber) SGB Series Blender Model Number SGB-900 Max Blend Capacity 318 KG/HR 220V Serial Number 060701R 1Ǿ Date of Manufacture 06/2002 4.5A Over-current Protection Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply 4.14 bar (60 psi) Mixer Speed 16 RPM Blender Mass 400 lbs/(180 KG)

  • Page 107: Appendix

    The following is a listing of the selections that are “field” programmable, followed by the procedure for doing so. This menu is accessed by pressing the Sterling icon when in the “Setup” Directory Screen menu. Touch this icon and...

  • Page 108: Factory Setup Menu

    Select a Feeder Stop the Meter Target Weight Change Method Meter Data Go back to Sterling Engineering Only Directory Advanced Weight Options Screen This screen allows you to modify the weight filter, adjust the mechanical time to settle the...
  • Page 109 Adjust the limit for Weight Filter “Hopper Over Max Weight” Weight/Sec. Filter Adjust Settle Time Go back to Sterling Engineering Only Directory Feed Algorithm This screen allows the user to configure how the Options Screen blender metering algorithm works. The user can...
  • Page 110 “Batch % for Feeder Cal” setting might be set too high. Consult Sterling if this problem arises. The current feeder calibration values are also shown on this page. It is not necessary to perform feeder calibrations.

  • Page 111: Customer Setup Menu

    Regrind and only one hopper must be configured for Virgin material. If this is incorrect, a message will be given on the Recipe Screen. Go back to Sterling Engineering Only Directory. 12-1-3 Customer Setup Menu Units This screen allows the user to change the blender’s unit...
  • Page 112 Unauthorized changes may prevent the blender from operating properly and may void part or all of the warranty. Call the Sterling 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.
  • Page 113 Information included in this manual is subject to change without notice. Remember: Blender controller default password is “5413” Service Notes SGB Batch Blender with Mitsubishi Controller Page 111 of 118...

  • Page 114: Passwords

    12-2 Passwords User Password “5413” Maintenance Password “3145348” CAUTION! Maintenance password should only be supplied to qualified personnel! The program can be compromised. 12-3 Default Values (factory defaults shown): SGB BLENDER CONFIGURATION PARAMETERS Model Number/Type SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 RECIPE FORMAT Recipe Entry Mode QUICK SET...

  • Page 115: Alarm Setup

    Dump Delay Dump Cycles Mixer Dump Time Continuous/Timed Mixing TIMED USER PASSWORD User Password 5413 Maintenance Password 3145348 SGB BLENDER CONFIGURATION PARAMETERS Cont’d. Model Number/Type SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 ALARM SETUP Hop1 Continue/Stop on Out of Material Hop2 Continue/Stop on Out of Material Hop3 Continue/Stop on Out of Material...
  • Page 116 Hop6 Allowed Underfeed Double Gate Threshold Out of Material Retry limit before alarm Batches for process rate Process Rate Filter SGB BLENDER CONFIGURATION PARAMETERS Cont’d. Model Number/Type SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 FEED CAL OPTIONS Hop1 Batch % for feeder Hop2 Batch % for feeder Hop3 Batch % for feeder Hop4 Batch % for feeder...
  • Page 117 Service Notes SGB Batch Blender with Mitsubishi Controller Page 115 of 118...
  • Page 118 Service Notes Page 116 of 118 SGB Batch Blender with Mitsubishi Controller...
  • Page 119 Service Notes SGB Batch Blender with Mitsubishi Controller Page 117 of 118...
  • Page 120 Page 118 of 118 SGB Batch Blender with Mitsubishi Controller...

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