Sterling SLC 5/04 manual

________________________________ 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: _________________________ _________________________ _________[...]

Continuous Loss-in-Weight Blenders ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any damage that m ight have occurre d in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Dam[...]

Continuous Loss-in-Weight Blenders iii 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) [...]

Continuous Loss-in-Weight Blenders iv Table of Contents CHAPTER 1: SAFETY ................................................................. 6 1-1 How to use this manual ............................................................................................... 6 Safety symbols used in this m anual ...............................................[...]

Continuous Loss-in-Weight Blenders v MAINTENANCE .......................................................................... 52 Preventative maintenance schedule .................................................................................... 52 APPENDIX .................................................................................. 54 6-1 Wa[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 6 Allen-Bradley Controls 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 purpo se is to assist you in applying efficient, proven techniques that enhance equipment productiv[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 7 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 PE Protected Earth Ground Shear Hazard - Rotating Auger Lifting Poi[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 8 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, n[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 9 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar wi[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 10 Operator Responsibility The operator’s responsibility does not end with e fficient 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 inc[...]

Continuous Loss-in-Weight Blenders Chapter 1: Safety 11 • 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 esse[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for co ntinuous loss-in-weight blenders of various blending rates and specifications. See Figure 1 below for a list of available model[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 13 2-3 Typical Features & Components Mechanical Features • Blender automatically adjusts individual feeders to match learne d extruder rate at the ratio required. • Upper material supply hoppers with conical re-fill valves and dust boots. • Individual ingredient weigh ho[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 14 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 com ponents (See Figure 2 below): • Ingredient supply/re-fill hoppers • Ingredient weigh hoppers [...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 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[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 16 Ingredient Metering/Transport Auger Assemblie s 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 [...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 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 constru[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 18 PLC Control Panel The PLC control panel may be mounted on the side o f the blender frame, or remote mounted near the blender. It uses an Allen-Bradley SLC 5/04 programmable cont roller with standard 24 vdc input output cards. This design provi des excellent blender performance [...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 19 2-4 Options The following is a list of options, which y our 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 (Re quires[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 20 2-5 Safety Device s 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 equipm ent. Inste[...]

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 21 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. T he safety devices that are used on the continuous loss-in-weight bl enders are primarily concerned with electrical power disconnection and the disabling of moving part s that may need to [...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 22 Chapter 3: Inst allation 3-1 Uncrating the Equipment Continuous loss-in-weight blenders are shipped bolted on a skid, enclosed in pla stic 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 installe[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 23 Site Requirements This section describes site requirements in detail. These requirements are broken down into mechanical mounting, electrical connecti ons and pneumatic connections. Since the continuous loss-in-weight blender is available in several different mounting arrangem ents, it i[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 24 Note: Never weld on the blender’s fr ame, machine or mezzanine without first removing the contro l panel and verifying that the blender’s power is disconnected. Mezzanine Mount In a mezzanine mount application, review th e following items before installation begins. First, verify the[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 25 Note: Ensure that the feed tube angle is steep enough (60 degrees is recommended). Note: Some mezzanine mount applications w ill require the blending system’s lower mass flow hopper be mounted on the ex truder throat. The metering section will be mounted on a small stand on the mezzani[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 26 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 [...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 27 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 plumbi ng to a single ¼” standard pipe thread fitting. The blender requires a maximum of 60 PSI of compressed[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 28 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 s ystem. 1. Visually inspect the extruder or blender mounting location for obstructions. 2. Re[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 29 3-6 Set-up This section will discuss the mechanical setup a nd control system setup of the continuous loss-in-weight blending system. After reading this section, you should be fam iliar with the mechanical setup and the electronic control setup of the blending s ystem. Load Cell Adjustme[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 30 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 lubricati on unit, if required. Verify that 60 psi (4.14 bar) of clean, dry compressed a[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 31 Controller Setup This section describes the proper setup of the c ontinuous loss-in-weight blending system control parameters. These parameters are ope rator changeable; however, these items should only require setup during the initial installation. Only authorized personnel should chang[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 32 will suffice. The weight will be in pounds, unl ess 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 capaci[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 33 Touch the “ACS Group” logo in the upper left ha nd corner. You will be prom pted to enter a password - it is “5413”. You will see the “Password Accep ted” screen, now press “OK”. Touch the “Calibration” button.[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 34 Touch “Scale” button Find your calibration weight that shipped with th e ble nder 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 em pty then touch Set Zero . 3. Hang [...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 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 36 Touch “Feeder” button Feeder Calibration is carried out as follow s: 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 hoppe[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 37 Figure 12: Hopper Sizes Hopper Diameter (inches) Approximate Hopper Capacity (@35 lbs. / cu. ft.) 9 7 12 14 14 18 20 40 24 60 Above lists standard sizes and can vary depending on the blender requireme nts and rates to be blended. Larger hopper sizes are available on custom order. Setting[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 38 Touch “ Hopper Setup” Touch the box next to the hopper number that y ou 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 [...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 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 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 ar[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 41 First you must get to the Alarm Setup Page. To d o this; Touch the “ ACS Group” l ogo . Enter the password and touch “ OK” Touch “ Alarm Setup” .[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 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, s[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 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 44 Touch the box that says “ English Units” to toggle between English and Metric ****Note, you must re-calibrate the blender and reset the in ventory values if you change this value.*** How to use FIFO Diagnostics First you must get to the FIFO screen. Touch the “ ACS Group” logo.[...]

Continuous Loss-in-Weight Blenders Chapter 3: Installation 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 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 o ut table. It [...]

Continuous Loss-in-Weight Blenders Chapter 4: Operation 47 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 av ailable on the conti[...]

Continuous Loss-in-Weight Blenders Chapter 4: Operation 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 mate rial increases in the mass flow weigh hopper, th e controller will adjust the blender feeders out put to match the calculated processing machine rate. The [...]

Continuous Loss-in-Weight Blenders Chapter 4: Operation 49 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 sh[...]

Continuous Loss-in-Weight Blenders Chapter 4: Operation 50 “Invento ry” page ¾ Clear Invent ory ¾ “Next” returns to “ R eci pe” page “Setup” Page ¾ Touch the AC S icon and ent er in the “user pa ssword” Hopper Setup ¾ Hopper size “Recipe” Page (Start) ¾ Extruder RP M is displayed ¾ Extruder thr oughput is displayed ¾ [...]

Continuous Loss-in-Weight Blenders Chapter 4: Operation 51 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 y ou to the page to manually run the motors.[...]

Continuous Loss-in-Weight Ble nders Chapter 5: Maintenance 52 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 re grind agitators, meteri ng augers, and optional discharge slide gates. The checklist b[...]

Continuous Loss-in-Weight Ble nders Chapter 5: Maintenance 53 Note: Other service problems or questions can be answered by contacting the Service Department.[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 54 Chapter 6: Appendix 6-1 Spare Parts Typical Blender Parts List # DESCRIPTION 015 060 100 Lid (0.2 to 1.6 cu. ft. vacuum receivers) 08223-1 08278A 08412-1 1 Lid (3.0 and 6.0 cu. ft. vacuum receivers) N/A N/A A0770325 2 1/8” NPT fitting 35085K and 35086K 3 1/4” NPT fitting 35154 and 35155 [...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 55 Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equi pment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius (104 degrees Fahrenheit) – Maximum 3. Humidity range: 50% relative humidity [...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 56 6-2 Addendum (Service Supervisor Information) Caution! After all selections are made: Keep p ressing the “Done” key until the unit returns to the Recipe menu. Passwords • User Password “5413” • Maintenance Password “3145348” Caution! Maintenance password should only be suppli[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 57 Once you access the Engineering Menu you will see the following. This is where you make adjustments to fine t une 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 [...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 58 Feed Factor Filter This filter allows you to set the number of snap shots that the FIFO page looks at to find the average deviation. Making this number bigger will cause the feeder to m ake changes slowly, and decreasing the number will make changes f aster. You may want to make this number [...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 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 num ber in the FIFO table. For quicker FIFO updates you would decrease this number. For a m ore stable process you would incr[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 60 PID Integral Constant Works the same as the Gain. Feeder Speed Limits This allows you to set the minimum and maxim u m speed for the motor dr ives as a percentage. The drives are not supposed to be run at less than 8 hertz and should not be run a bove 115 hertz. Extruder RPM Options This giv[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 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 extrud er speed updates from the prox. Ext[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 62 Advanced Alarm Options This alarm is for no material flow through a a uger, 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 lo ss) through a hopper, to determine if an alarm is warranted. No Flow Bits This is[...]

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 63 6-3 Technical Assistance Parts Department Call toll-free 7 am–5 pm CST 800.423.31 83 or call 262. 641.8610 Fax 262.641.8 6 53 The ACS Customer Service Group will provi de your company with genuine O EM quality parts manufactured to engineeri ng design specifi cations, which will maximize y[...]