Acs Blender Bd Users Manual 882.02148.00 Gravimetric Batch With Red Lion

2015-02-05

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Gravimetric Slide Gate Auger Batch Blender
Red-Lion Display
Models: BD, CSG, SGBD
Part Number: 882.02148.00
Bulletin Number: BLN1-600A
Effective: February 1, 2013
Write Down Your Serial and Software Revision 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 2013
All rights reserved.
ii
Shipping Info
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.
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 before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
! Bill of lading
! Packing list
! Operating and Installation packet
! Electrical schematic and panel layout drawings
! Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
immediate assistance, please contact the correct facility located in the technical assistance
section of this manual. Have the order number and item number available. Hold the items
until you receive shipping instructions.
Storage and Handling
Keep equipment in a clean, dry location when storing/handling. Environment should not
exceed -25°C to 65°C (-13°F to 149°F) with no icing.
iii
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
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.
iv
Table of Contents
CHAPTER 1:!SAFETY ................................................................ 7!
1-1!How to Use This Manual .............................................................................................. 7!
Safety Symbols Used in this Manual ..................................................................... 7!
1-2!Warnings and Precautions ......................................................................................... 10!
1-3!Responsibility ............................................................................................................. 11!
General Responsibility ........................................................................................ 11!
Operator Responsibility ....................................................................................... 11!
Maintenance Responsibility ................................................................................ 13!
Reporting a Safety Defect ................................................................................... 13!
CHAPTER 2:!FUNCTIONAL DESCRIPTION ........................... 14!
2-1!Models Covered in This Manual ................................................................................. 14!
2-2!General Description .................................................................................................... 14!
Accessories ......................................................................................................... 14!
Customer Service ................................................................................................ 14!
2-3!Typical Features and Components ............................................................................. 16!
Mechanical Features ........................................................................................... 16!
Controller Features .............................................................................................. 16!
System Component Description .......................................................................... 17!
Supply Hoppers .................................................................................................... 17!
Slide Gates ........................................................................................................... 18!
Weigh Hopper ...................................................................................................... 19!
Mix Chamber ....................................................................................................... 21!
Operator Control Panel Display ........................................................................... 22!
2-4!Optional Components ................................................................................................. 30!
Pneumatic Slide Gate below Mixer ..................................................................... 30!
Low Level Sensors .............................................................................................. 30!
Remote Touch Screen ........................................................................................ 30!
Mezzanine and Floor Stands .............................................................................. 30!
HD—“Heavy Duty”! RD—“Regular Duty” ....................................................... 31!
Regrind Auger Metering (R.A.M.) Hopper ........................................................... 31!
Additive Feeder Hopper ...................................................................................... 32!
Take-off Compartments ...................................................................................... 32!
2-5!Safety Features .......................................................................................................... 32!
Safety Circuit Standards ..................................................................................... 33!
Fail Safe Operation ............................................................................................. 33!
Safety Device Lock-Outs ..................................................................................... 33!
Twist Cap Plug Connected to Each Feeder Auger Motor ................................... 34!
CHAPTER 3:!INSTALLATION ................................................. 36!
3-1!Uncrating the Equipment ............................................................................................ 36!
3-2!Mechanical Installation ............................................................................................... 36!
Site Requirements ............................................................................................... 37!
Mounting Configurations ..................................................................................... 37!
Machine Mount .................................................................................................... 37!
Mezzanine Mount ................................................................................................ 38!
v
Floor Mount (Central Blender) ............................................................................ 39!
3-3!Electrical Connections ................................................................................................ 39!
3-4!Pneumatic Connections .............................................................................................. 41!
3-5!Initial Set-up ................................................................................................................ 41!
Mechanical Set-up .............................................................................................. 42!
Stroke Limiters for Metering Gates ..................................................................... 42!
Weigh Hopper Installation ................................................................................... 43!
Final Connections ................................................................................................ 43!
Controller Set-up ................................................................................................. 44!
Blender Calibration .............................................................................................. 46!
Alarm Setup ......................................................................................................... 49!
Network Setup ..................................................................................................... 51!
Display IP Address and Setting the Time/Date ................................................... 51!
Configure the blender for LBS or KGS. .............................................................. 52!
Mixer and Dump Setup ........................................................................................ 52!
3-6!Initial Startup ............................................................................................................... 53!
CHAPTER 4:!OPERATION ...................................................... 54!
4-1!Start-up ....................................................................................................................... 54!
General Operation ............................................................................................... 54!
Quick Start Procedure ......................................................................................... 55!
New Recipes ........................................................................................................ 55!
Existing Recipes .................................................................................................. 55!
4-2!Operation Procedures ................................................................................................ 56!
Operator Displays ................................................................................................ 56!
Recipe Entry Formats.......................................................................................... 61!
“EZ Recipe” Mode (Most common in injection molding) .................................. 62!
“Percentage” Mode (Most common in extrusion and blow molding) ................. 64!
“Parts” Mode (Often used in Compounding Applications) ................................. 64!
Recipe Setup ....................................................................................................... 64!
Mixer and Dump Setup ....................................................................................... 68!
Alarm Messages ................................................................................................. 70!
Printer Features ................................................................................................... 72!
Color Changes .................................................................................................... 73!
4-3!Shut-down .................................................................................................................. 75!
CHAPTER 5:!MAINTENANCE ................................................. 76!
5-1!Preventative Maintenance Schedule .......................................................................... 76!
5-2!Preventative Maintenance .......................................................................................... 77!
5-3!Corrective Maintenance .............................................................................................. 78!
CHAPTER 6:!TROUBLESHOOTING ....................................... 80!
6-1!Introduction ................................................................................................................. 80!
CHAPTER 7:!APPENDIX ......................................................... 85!
Annex B Information ............................................................................................ 85!
7-1!Drawings and Diagrams ............................................................................................. 86!
Final Assembly .................................................................................................... 86!
DM: Diamond SQ: Square .................................................................................. 86!
vi
Mixer Sub-Assembly ........................................................................................... 87!
Hopper Sub-assembly ......................................................................................... 89!
Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional) .................. 90!
Weigh Hopper Sub-assembly ............................................................................. 92!
Slide Gate Sub-assembly .................................................................................... 93!
Knife Gate Sub-assembly HD (Optional) ............................................................ 94!
Knife Gate Sub-assembly RD (Optional) ............................................................ 95!
Control Panel Layout ........................................................................................... 96!
7-3!Spare Parts Kits * ....................................................................................................... 98!
7-4!Addendum (Service Supervisor Information) .............................................................. 99!
Programmable Settings ..................................................................................... 100!
Advanced Setup Menu ...................................................................................... 100!
7-5!COMMUNICATIONS AND WEB SERVER .............................................................. 109!
7-6!Technical Assistance ................................................................................................ 116!
Parts Department .............................................................................................. 116!
Sales and Contracting Department ................................................................... 116!
Facilities ............................................................................................................ 116!
BLN1-600A Chapter 1: Safety 7 of 116
Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
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 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 blender 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 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. 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 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.
BLN1-600A Chapter 1: Safety 8 of 116
Figure 1: Safety Tags and Warning Labels
Hazard Alert Symbol
Description/Explanation
Preventative Maintenance
Pinch point slide gate.
Hands can become
entangled or cut if they
enter the danger zone of
gears or cutting shears.
Every month inspect the
shears/blades for any type of
wear. For further information
see the Maintenance Chapter
in this manual.
High voltage inside
enclosure. The electrical
enclosure is supplied with
3-phase electrical power.
Use caution when using or
maintaining this product.
Every six months inspect all
electrical connections for
secure attachment. For
further information see the
Maintenance Chapter in this
manual.
Shear point rotating mixer.
Hands can become
entangled or cut if they
enter the danger zone of
gears or cutting shears.
Every month inspect the
shears/blades for any type of
wear. For further information
see the Maintenance Chapter
in this manual.
Shear hazard rotating
auger. Hands can become
entangled or cut if they
enter the danger zone of
gears or cutting shears.
Every month inspect the
shears/blades for any type of
wear. For further information
see the Maintenance Chapter
in this manual.
BLN1-600A Chapter 1: Safety 9 of 116
Mandatory Symbol
BLN1-600A Chapter 1: Safety 10 of 116
1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, 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.
BLN1-600A Chapter 1: Safety 11 of 116
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.
Becoming familiar with materials, inspection, speed limitations, and guard maintenance and
total user responsibility will assist you in learning potential areas in need of observation for
danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, 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 every day, safety is 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.
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.
BLN1-600A Chapter 1: Safety 12 of 116
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:
• Remove all tools from the unit;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the metering or If your
blender has been inoperative or unattended, check all settings before starting the unit.
Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual blender action
• leakage
• improper maintenance
• 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.
• 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 an blender. In addition, cover or tie back long hair.
• 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.
BLN1-600A Chapter 1: Safety 13 of 116
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.
BLN1-600A Chapter 2: Functional Description 14 of 116
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for the BD, CSG,
and SGBD Series slide gate blenders of various blending rates and specifications. See below
for a list of available models.
• 150 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
• 500 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
• 900 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
• 2500 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
• 4000 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
• 6000 lbs/hr Slide Gate Batch Blender with Allen-Bradley Controls
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 service. All slide gate blenders are
sized to meet the specific requirements stated by the Customer at the time of purchase.
2-2 General Description
All blenders are designed to blend plastic pellets and regrind, and supply the blended material
to the processing machine. Standard equipment is not designed to blend powder or any other
materials.
Accessories
The manufacturer offers a variety of standard options for blenders including floor stands,
RAM feeders, loading equipment, 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.
• 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.
BLN1-600A Chapter 2: Functional Description 15 of 116
Figure 2: Equipment Specifications
Figure 3: Typical Blender Assembly
150 (*1) 500 900 2500 4000 6000
150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725)
2 to 4 2 to 6
2.0 (50) 2.5 (63)
1.5 (38) 2.0 (50)
0.7 (20) 3.0 (85)
0.2 (5) 2.7 (77)
0.07 (20) 0.18 (50) 0.38 (11) 0.82 (23) 1.23 (34) 2.17 (61)
1.5 (0.7) 4 (1.8) 8 (3.6) 25 (11.3) 35 (15.8) 45 (20.4)
1 @ 5 kg 2 @ 3 kg 2 @ 5kg 2 @ 10 kg 2 @ 15 kg 2 @ 20 kg
0.18 (5) 0.25 (7) 0.56 (16) 1.1 (31)
1/8 (0.09) 1/3 (0.249)
42
2.5 (63)
250 (115) 375 (170) 450 (205) 650 (295)
350 (160) 425 (190) 550 (250) 800 (360)
Height (*3) 34.5 (875) 51.5 (1308) 56.5 (1435) 69.5 (1765) 85.5 (2172) 89.5 (2337)
Width (*3) 26.0 (650) 37.5 (952) 37.0 (940) 45.5 (1156)
Depth (*3) 22.0 (560) 37.0 (940) 40.0 (1016) 46.5 (1181)
(*3) Measurements describe standard unit without feeder or RAM hoppers.
Approximate Dimensions, in. (mm)
3.0 (76.2)
4.0 (102)
Note: Blender models with 7th and 8th component metering include Allen Bradley 10 inch color touch screen standard.
Weight of Machine (approx.), lbs. (kgs)
1100 (500)
Shipping Weight (approx.), lbs. (kgs)
1300 (590)
(*4) See page 75 for important rate information concerning each model's maximum blending rate.
(*1) Compressed air loaders CANNOT be used to load 150 # blenders.
(*2) Hopper capacity measured excludes straight wall section and is based on vacuum receiver use. Approximate value.
57.5 (1461)
57.0 (1448)
Mixer Capacity, cu.ft. (l.)
Mixer RPM
21
22
Blended Material Discharge Opening, in. (mm)
2.72 (77)
Mixer Motor Size, HP (kw)
1/6 (0.124)
1 (0.75)
Supply Hopper Capacity - Minors, cu.ft. (l.) (*2)
1.0 (28)
6.0 (170)
Weigh Hopper Capacity, cu.ft. (l.)
Typical Batch Size, lbs. (kgs)
Load Cell Capacity, kgs
Slide Gate Size - Minors, in. (mm)
1.5 (38)
3.0 (75)
Supply Hopper Capacity - Majors, cu.ft. (l.) (*2)
1.4 (40)
7.5 (212)
Dimensions and Specifications
Maximum Blending Rate, lbs/hr (kgs/hr) (*4)
Number of Materials to be Blended
2 to 8
Slide Gate Size - Majors, in. (mm)
2.0 (50)
4.0 (100 )
BLN1-600A Chapter 2: Functional Description 16 of 116
2-3 Typical Features and Components
Mechanical Features
• Exclusive diamond design slide gate metering assemblies meter a large range for free-
flowing pellet materials
• Adjustable slide gate stroke limiting restrictors provided for accurate metering of
minor ingredients (not available on 150 models, or removable hopper components)
• Removable stainless steel weigh hopper and mixing components
• Powder coated mild steel material supply hoppers with machined polycarbonate clean-
out doors and optional material drains (stainless steel hoppers on 150 models)
• Precision 0.02% span accurate cantilever load cell weighing system
• Interlocked safety system shuts off compressed air and electricity if mixer is opened
• Compressed air hose with nozzle provided as a convenience for clean-out
Figure 4: Typical Red Lion Touch Screen Display
Controller 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
• Auxiliary alarm contact
• Your touch-screen panel may differ slightly from shown.
BLN1-600A Chapter 2: Functional Description 17 of 116
• 100 recipe storage book
• Three (3) types of recipe entry procedures available:
o “EZ Recipe” mode (up to 8-component) recipe entry. Color and additives
are metered as a percentage of the virgin material.
o Percentage mode recipe entry. Ingredients are metered as a percentage of
the overall batch.
o Parts mode recipe entry (i.e. 500:1) Ingredients are metered as a ratio to
each other within the batch
• Full control diagnostics
• Serial printer and communications ports
System Component Description
This section describes the various components of the blending system.
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 blending system does not include any level indication devices on the unit. Optional low-
level sensors are available. The blender controller will alarm if it runs out of material while
trying to make a batch, but low-level sensors will alert floor personnel to the problem sooner.
Many hoppers are equipped with a sight glass and/or access door.
Figure 5: Typical Hopper Assembly
BLN1-600A Chapter 2: Functional Description 18 of 116
Slide Gates
Air operated slide gates are provided to meter the majority of pellet ingredients on Slide Gate
blenders.
A stroke limiter (included) can be installed on the metering gates to limit their travel. This
device decreases the stroke of the gate and reduces the metering orifice of the valve. The
unique diamond gate provides a square opening at any stroke length, providing more
consistent flow from smaller valve openings than conventional slide gates. This stroke
limiter may be necessary to accurately meter low percentage ingredients.
The air cylinders operating the slide gate are rugged, stainless steel cylinders designed for
industrial use.
Slide gates create a pinch-point hazard.
Always disconnect and lockout all electrical power and pneumatic (i.e.
compressed air) sources prior to servicing or cleaning any blender,
including all Batch models. Failure to do so may result in serious injury.
DIAMOND GATE CLOSED
DIAMOND GATE 3/4 CLOSED
DIAMOND GATE 1/2 CLOSED
DIAMOND GATE OPEN
• The metering range assumes 1/8” diameter free-flowing plastic pellets
weighing approximately 35 lbs./cu. ft. This is meant to be an approximate
sizing recommendation and can vary with different bulk density resins,
pellet configuration, etc.
• The unique diamond gate
provides a constant aspect
opening that remains
square regardless of the
stroke length of the
cylinder. This design
provides a wider cross
sectional opening when
approaching a closed
position, and provides
better flow of plastic pellets
out of the opening.
BLN1-600A Chapter 2: Functional Description 19 of 116
Figure 6: Typical Slide Gate Assembly
Each of the diamond gate air cylinders is actuated by a solenoid valve, which are controlled
by the blender PLC.
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.
If the power is interrupted to the blender, the metering valves will return to the closed
position, to prevent material from over-filling the weigh hopper/mix chamber.
Weigh Hopper
On a Slide Gate blender, the weigh hopper rests on each side on a precision cantilever load
cell. To remove the weigh hopper, disconnect air line then lift the hopper from the bottom,
hold the dump door closed, and slide it out once clear of the locating tab on the bracket above
the load cell.
Once the hopper has been cleaned, reposition it onto the load cell brackets, using care not to
damage the load cells. Position the hopper as close to the center position between the load
cells as possible.
• If the blender is in metering mode with one of the slide gates open, do not
open the front door of the blender!
• The safety switch shuts off the air supply to the blender. An open feeder
slide gate stays open, and an overflow of the weigh hopper can occur!
• Use care when replacing the weigh hopper, since the load cells are delicate
weighing instruments and can be easily damaged. Do not use force to push in
the weigh hopper. If it is positioned properly, it will slide in very easily.
• Load cells, if damaged, will have to be sent back to the manufacturer for
testing and evaluation.
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Figure 7: Typical Weigh Hopper Assembly
The weigh hopper dump door holds the material until it is dumped into the mixing section.
The cylinder is actuated by a solenoid in the valve stack on the side 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. When the weigh hopper discharge cylinder solenoid valve is not
electrically energized, it will provide air pressure to the air cylinder and hold the shaft in an
extended position, holding the dump valve closed.
When the air cylinder is actuated, the air pressure to the dump valve will be removed, causing
it to open.
The air cylinder on the weigh hopper includes a spring return to allow the cylinder to retract
in the absence of air pressure on the cylinder. This will cause the dump valve to open.
The pneumatic system used on the Slide Gate blender, like all
pneumatic systems, is highly sensitive to oily, dirty, wet or contaminated
air. If oil, dirt, water, or any other air-borne contaminates enter the
system, the components could be damaged and injury to the operator
could result. A proper air supply must be supplied to the blender.
When the safety circuit is disabled, the air pressure to the cylinder will drop off by shutting
off all the air supply to the valve stack with the pilot operated master air valve. This will also
cause the weigh hopper discharge door to open.
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Mix Chamber
All of the 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.
Figure 8: Typical Mixer Assembly
The mixer is designed to provide bi-directional mixing action and can be easily taken apart
for cleaning. This design is standard on all Slide Gate blenders.
Blades may be sharp!
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Operator Control Panel Display
The operator control panel includes an 8 foot (2.4 m) cable and can be remote mounted (not
recommended) adjacent to the blender. The panel can be unplugged and removed if
necessary.
A programmable logic controller (PLC) controls the blender operation. This design provides
excellent blender performance along with an easily replaceable control panel in the unlikely
failure of any computer or electronic part.
The display menu format is very simple. After installation and setup, simply enter in the
recipe and start the blender. See the following pages for controller pushbutton & touchscreen
tags along with typical operator screens.
If it is desired to have a local display and control of the blender closer to a remote operator
station, an optional remote mount operator panel is available.
STARTUP SCREEN
The recipe screen will
automatically be shown
in 5 seconds. Touch
here to bypass startup
delay
Display & PLC
Software versions
shown. The first 2
digits should be the
same.
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Changing the Language
Language Selection Page
Touch here to bring up Language Selection Page
Touch the Flag of your
Country to change the
language
BLN1-600A Chapter 2: Functional Description 24 of 116
Recipe Page
Touch screen interface is unlocked. To lock
touch the lock icon and enter in the password.
Touch screen interface is locked. This
prevents someone from starting/stopping the
blender or changing the recipe. To unlock
touch the lock icon and enter in the password.
Blender is not running. Touch to start
blender.
Blender is running. Touch to stop blender.
The blender will then stop after it has
completed the current batch.
Weigh hopper closed / Weigh hopper open
Mixer not full / Mixer Full
Mixer Knife Gate Closed / Open
Ingredient Feeding
Ingredient Alarming
Accept / Undo Recipe Change
Cleanout blender when
blender is stopped
Show Inventory Data
Recipe Book
Abort current batch
Start/Stop blender
Lock/Unlock
interface so no
changes can be made
Access to Setup
Touch to change
recipe value
Mixer Status
Recipe Mode
Access to Setup is not
secured (see Advanced
Settings)
Simulator Enabled for Demo
Ingredient Number and
Type
Hopper Weight
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Entering a Recipe
REQUIREMENTS FOR A VALID RECIPE
EZ Mode
Regrind hopper cannot be over 100%.
Multiple Virgin hoppers must total 100%.
Percentage Mode
Recipe Total must add to 100%.
Parts Mode
All entries are valid.
Touch to change
recipe value
After typing in new
value touch here to
accept
Touch here to Cancel
Entry
Touch here to Accept
the new recipe
Touch here to Undo
recipe change
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Recipe Book
REQUIREMENTS FOR A VALID RECIPE
EZ Mode
Regrind hopper cannot be over 100%.
Multiple Virgin hoppers must total 100%.
Percentage Mode
Recipe Total must add to 100%.
Parts Mode
All entries are valid.
Touch here to bring
up the Recipe Book
Modify any recipe
value in the stored
recipe
Touch here to close
the Recipe Book
without loading a
selected recipe
Load the selected
recipe into the
blender
Touch arrows to
increase/decrease
recipe number. You
can also enter in the
recipe number if you
know it.
If you’ve modified a
recipe the SAVE icon
will appear. Touch to
save changes before
leaving the recipe
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Cleanout Mode
3
Touch here if blender
is stopped
Touch hopper icon to
open/close feeder
Touch weigh hopper
icon to open/close
Touch mixer icon to
start/stop
Touch knife gate icon
to open/close
Touch here to Cancel
Cleanout mode
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Inventory Page
Touch here to bring
up the Inventory Page
Material weight that
has been weighed and
dispensed through the
weigh hopper
Print Inventory
Magnified TOTAL
INVENTORY page
for long distance
viewing on OI units
Clear Inventory. You
will have to enter
your password and
confirm.
Touch here to close
the Inventory Page
Batches counted in
Total Inventory
Max Blender rate
with current recipe
Average Batch time
in seconds
Consumption rate of
process
Touch here to close
Magnified View
BLN1-600A Chapter 2: Functional Description 29 of 116
Inventory Shutdown Event
The blender has a feature called “inventory shutdown”. This is typically used to fill gaylords
without the need of a “full” prox for the bin. The blender can be configured to perform this
feature by entering in an “inventory shutdown value” under “Recipe Format” found under
“Setup” (see setup section for more details). Once a recipe with an inventory shutdown value
is started the blender will continue to make batches until the inventory shutdown value has
been reached. This is checked after the batch dumps, so you can end up with a value that is
nearly 1 batch greater in weight than the programmed inventory shutdown value. Once the
inventory shutdown value is reached the blender stops making batches, the alarm horn/flasher
is energized, and the page below is shown.
Touch here to close
this page and go back
to the recipe page
Touch here after
you’ve changed the
Gaylord box to restart
the weight counter
and the blender. This
does not clear the
inventory shown on
the inventory page.
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2-4 Optional Components
The following is a list of options, which your blender may have been equipped with:
Pneumatic Slide Gate below Mixer
The Batch 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. Control of the mixer function is described below, and is determined
by the position of the “knife gate switch” located on the side of the back control panel.
Slide gates create a pinch-point hazard
Figure 13: Mixer Slide Gate Switch Positions
Position
Description
AUTO
Slide gate functions are automatically controlled by the blender
controller
OPEN
Slide gate open all the time
CLOSE
Slide gate closed all the time
Low Level Sensors
Detect material supply problems before blender supply hoppers are empty.
Remote Touch Screen
This section describes the optional Remote Touch Screen. It is useful in situations when the
access to the control panel is difficult or limited. This remote control panel may be located up
to 50 cable feet away from the blender control panel. (Note: a signal amplifier may be
required for long distances. Consult factory with actual application.)
The remote interface provides the operator with all the functions of the standard Batch
blender control panel. The keypad and display are identical to the blender panel.
Every Batch blender panel includes a remote interface connection, and simply plugs into the
appropriate connector. The remote touch screen is an option and is not included with the
standard blender.
Mezzanine and Floor Stands
Supports blenders in mezzanine mount and freestanding applications.
Figure 14: Typical Floor Stands (Surge Hopper Stand & Gaylord Fill Stand)
• The Remote Touch Screen option provides a second operator control.
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HD—“Heavy Duty” RD—“Regular Duty”
(Some assembly may be required.)
Regrind Auger Metering (R.A.M.) Hopper
Used for feeding difficult regrind materials.
Figure 15: Typical R.A.M. Hopper Blender Configuration
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Additive Feeder Hopper
Used for feeding pelletized additive, typically used on blenders with more than six
components.
Figure 16: Typical Additive Feeder Configuration
Take-off Compartments
Allows material to be metered into a vacuum conveying system.
2-5 Safety Features
This section includes information on safety devices and procedures that are inherent to the
Gravimetric Batch 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
BLN1-600A Chapter 2: Functional Description 33 of 116
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) article 1910.147 and NFPA 70 and 79 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 Batch
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 able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on the Batch Blenders are primarily concerned with pneumatic and 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, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these blenders are equipped with a line cord
plug (Shown in figures 17 and 18). This allows the operator or maintenance personnel to
unplug the unit from its power source and tag it out. The plug can then be tagged with any
number of approved electrical lockout tags available at most electrical supply stores.
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Figure 17: Electrical Disconnect Plug
Twist Cap Plug Connected to Each Feeder Auger Motor
The cap plug must be turned counter-clockwise to loosen 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. Disconnect plug before cleaning or
servicing motors or augers.
Figure 18: Twist Cap Plug
Motor
Unscrew and remove plug
from motor
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Figure 19: Electrical Safety Interlock Switch (Located on mixer door)
A unique electric safety switch is used to shut off power to the blender any time
the mixer door is opened. Do not alter or tamper with this switch in any way.
Always disconnect and lockout all electrical power and pneumatic (i.e.
compressed air) sources prior to servicing or cleaning the Batch Blender.
Failure to do so may result in serious injury. No one but the person who
installed the lockout may remove it.
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Chapter 3: Installation
3-1 Uncrating the Equipment
Batch Blenders are shipped mounted on a skid, enclosed in a plastic wrapper, and contained
in a crate.
1. Remove crate from around blender.
2. Secure strap of proper lifting capacity to both lifting lugs (See Figure 20 below.).
Use approved safety straps or chains to lift the blender at the marked lifting points.
3. Lift blender until strap is taut.
4. Remove bolts attaching bottom of blender to shipping skid, bolt located under mixer
drawer.
5. Lower blender slowly.
Figure 20: Blender Lifting Lugs (1 on each side)
3-2 Mechanical Installation
It is the intent of this section to familiarize the reader with the proper site requirements and
installation procedures of the Batch 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.
The installation procedure should be used as a general guideline for the proper installation
steps required to install the Batch blending system.
1. Lift blender and position over machine throat or floor stand.
2. Set in position and secure by tightening four grade 8 bolts. (Supplied by customer.)
BLN1-600A Chapter 3: Installation 37 of 116
3. Remove lifting strap.
4. If equipped; adjust the four leveling bolts on the floor stand blender support rails.
5. Mount the material conveying system receivers on the top of the blender supply
hoppers.
6. Align the weigh hopper on the load cell brackets with air cylinder toward rear of
blender. Carefully adjust the load cell brackets to ensure that the weigh hopper is
centered on the brackets without rocking. If for some reason the locating tabs do not
align with the weigh hopper, they can easily be loosened and adjusted.
7. Check the slide gate metering assemblies to ensure they are not damaged, and will
slide back and forth freely. These are the most important items on the blender,
besides the load cell and weigh hopper assemblies.
Site Requirements
This section describes site requirements in detail. These requirements are broken down into
mechanical mounting, electrical connections and pneumatic connections. Since the Slide Gate
Blender is available in several different mounting arrangements, it is necessary for the reader
to become familiar with the different arrangements.
Mounting Configurations
The Slide Gate Blending System 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 Slide Gate 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 Slide Gate blender flange (if the
optional pre-drilled holes were ordered). The Slide Gate blender can also be equipped with an
optional cast throat section with a drain port. This will bolt under the bottom plate of the
blender.
Verify that the machine throat is physically capable of supporting the Slide Gate blending
system with a full load of material and vacuum loading equipment installed.
• While in operation, the slide gate blender applies horizontal and vertical
pressures to the mounting flange. If there is a question as to the mechanical
stability of a mounting flange, contact the manufacturer’s engineering
department.
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.
• Use extreme care when tightening bolts on top of the load cells so you do not
spring the load cells. The load cells are extremely delicate and should be
treated with care!
BLN1-600A Chapter 3: Installation 38 of 116
• Allow at least 36” clearance around blender to provide adequate room for
cleaning, servicing, etc.
Using proper lifting equipment, lift the blender, using the lifting lugs attached to the top plate
of the blender. These lifting lugs can also be used to fasten horizontal or angled braces to the
blender if more stability is needed.
• Larger blenders need to be braced as part of the installation. Take care to insure
proper orientation with adequate access to operator controls, mix chamber, and
metering units
• Never weld on the blender, support stand, machine or mezzanine without first
removing the control panel and verifying that the blender is properly grounded.
Mezzanine Mount
In a mezzanine mount application, review the following items before installation begins.
First, verify the Batch mounting locations match the mezzanine supports. Verify that the
mezzanine is capable of supporting the blender with a full load of material and vacuum
loading equipment installed.
• While in operation, the batch blender applies horizontal and vertical pressures
to the mounting flange. If there is a question as to the mechanical stability of a
mounting flange, contact the manufacturer’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. Use aluminum tubing or smooth wall flex hose.
Figure 21: Typical Mezzanine Mounted Batch Blender
If possible, use rigid tubing. Some flex hose will tend to sag and generate static that could
cause de-mixing between the blender and the extruder.
BLN1-600A Chapter 3: Installation 39 of 116
Make sure that adequate space is around the blender (36” recommended) to allow proper
cleaning, servicing, etc.
Floor Mount (Central Blender)
maintenance. The operator and maintenance personnel must have access to 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. Using proper lifting
equipment, lift the Slide Gate blender into place.
Make sure that the blender is securely mounted to the floor before installing loading
equipment, loading with material, and starting.
Make sure that the blender location is adequately away from high traffic aisles, and that fork
trucks, etc. cannot damage the blender. Ensure that normal day-to-day operations will not
place the blending system at risk of damage.
Figure 22: Typical Floor Mount (Central) Blender Layout
3-3 Electrical Connections
The standard Batch blending system is designed to operate on 120-240/1/60 or 110-220/1/50
supply voltage. 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.
• The blender must be securely fastened to the floor before operating.
• Manufacturer assumes no responsibility for any damages resulting from
improper installation or improper handling during installation.
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If a step down transformer was provided, it should never be used to power anything other
than the blender. Loading equipment, etc. must be powered by another power source. As well
as possibly overloading the transformer, the additional equipment may induce power line
noise that may affect the operation of the blending system.
The transformer will be mounted and wired by the customer or your installer. If company or
local codes require fusing or disconnects, these items must be supplied, wired, and mounted
by the customer.
1. Provide a correctly sized and protected power supply to the unit.
2. If an electrical supply disconnect is not installed as a factory option, the customer
is responsible to properly size and install a suitable disconnect.
3. Refer to National Electric Code (NEC) 430-24-26 for proper feed conductor and
supply disconnect sizing.
4. Voltages must be within plus or minus ten percent (±10%) of the nameplate rating.
5. Maintain a safe ground and disconnect the power supply before servicing the unit
(NFPA Article 250).
A qualified electrician should make electrical connections and disconnect the
electricity when service calls are needed.
Improper electrical connections can
damage the unit and cause serious
operator injury or death!
MAKE SURE THAT ALL ELECTRICAL CONNECTIONS ARE
MADE BY A QUALIFIED ELECTRICIAN, AND THAT ALL
CONNECTIONS ARE TIGHT.
Ensure that the power entrance location on the blender panel remains unchanged. Make sure
that the proper size wire and proper wire routing techniques are used when installing the
• Each blending system MUST be connected to a separate source of power. Do
not connect other electrical equipment, especially self-contained hopper
loaders, on the same line as the blending system.
BLN1-600A Chapter 3: Installation 41 of 116
supply wiring to the control panel. Care must be taken to ensure that the supply wiring does
not interfere with the low voltage DC wiring.
The blender is equipped with a plug that functions as the disconnect device (See Figure 11 on
Page 27 for an example). The mating receptacle must be installed no higher than 5’ feet
(1.6 m) above the floor. Make sure your installation conforms to your regional electrical
standards.
3-4 Pneumatic Connections
The Batch blending system uses plant-supplied compressed air to operate the metering and
dump valves on the blender.
CLEAN AND DRY air must be supplied to the blender. The air supply should be filtered
through a 5 micron air filter with a water separator. Oil should not be used unless air dryers
are installed on the compressed air supply. In this situation, an oiler may be required on the
blender to keep the air cylinder seals lubricated.
Figure 23: Customer-Supplied Pneumatic Components
The manufacturer provides all pneumatic lines on the blender piped to a single ¼” NPT
standard pipe thread fitting. The Batch blending system requires approximately 1 cfm (1.7
m³/hr) @ 60 psi (4.14 bar) maximum air pressure for proper operation.
The working pressure of the blender cylinders is not to exceed 60 psi (4.14 bar). This is
adjustable by the regulator supplied on the rear panel of the blender. It is important to prevent
fluctuation in the air pressure to the blender by not installing the unit on an airline. If this is
the case, an accumulator tank with a check valve may have to be provided by the customer to
ensure the blender a steady air supply.
To prevent damage to the equipment, do not exceed 60 psi (4.14 bar) air
pressure.
Always disconnect the compressed air supply when working on any part of
the blender.
3-5 Initial Set-up
This section will discuss the mechanical setup and control system setup of the Slide Gate
blending system. After reading this section, you should be familiar with the mechanical setup
and the electronic control setup of the blending system.
• As this blender uses air for blender metering functions, it is very important
to supply clean, dry air to the blender. Dirty or oily air can affect blender
accuracy; result in poor performance, and cause injury. Provide a 5-micron
air filter on the air supply to the blender, and be sure excess oil is removed.
Also, use a dedicated line to ensure proper air supply.
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Mechanical Set-up
Stroke Limiters for Metering Gates
Stroke limiters are supplied on components 1 through 6 with all Slide Gate blenders to allow
standard metering gates to meter small amounts of low percentage additive materials.
Generally, the stroke limiter is not required on major ingredients (usually number 1 and 3)
and should be adjusted to the rear-most position. If they are used on components number 1
and 3 the throughput of the blender will be reduced.
To install the stroke limiter, drop it into the double slot on top of the gate assembly and
secure it in place with the button head screw that is provided. Be sure to use the lock washer
to prevent the stroke limiter from coming loose.
Figure 24: Stroke Limiters
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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.
Figure 25: Weigh Hopper
Final Connections
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.
• THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE
FREE FROM FRICTION, WITH NO MECHANICAL OBSTRUCTIONS
OTHER THAN THE LOAD CELL ITSELF.
• 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!
• Make sure that the blender is supplied with clean, dry,
60 psi (4.14 bar) compressed air.
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Controller Set-up
This section describes the proper setup of the batch 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.
A complete listing of all default values is provided at the end of this manual.
Touch here and enter
password (default is
5413) to access setup
BLN1-600A Chapter 3: Installation 45 of 116
Menu Structure for Batch Blenders
Recipe Page—Start
"Change Recipe Values by
touching the number you
wish to change
"Touch “Accept New Recipe”
button after you’ve made the
desired changes
"Touch “Undo” button to
cancel a recipe change
before accepting it
"Start or stop the blender by
touching the “Push to Start or
Stop” button
"Access “Recipe Book ” Page
"Access “Clean Out” Mode
"Access “Inventory” Page”
"Access “Setup” Page
"Lock/Unlock User Interface
“Recipe Book” Page
Save the running recipe to the
book.
•
Create/Edit a stored recipe
•Load a stored recipe
•Return to the Recipe Page
“Clean Out” Mode
•
Empty the blender hoppers
•Manually operate mixer,
weigh hopper dump gate,,
and slide gate below mixer
•View/test all inputs/outputs
on the blender
•Return to Recipe Page
“Inventory” Page
•View/print accumulated
inventories
•View batch time
•View maximum capacity
•
View average process rate
•Return to Recipe Page
•Magnify “Total Inventory”
“Setup” Page
•Touch the “ACS” icon and
enter in user password
Recipe Format
•Percentage, Parts, or
EZ mode
•Metering order
•Batch size
•
Inventory shutdown
•
“Batch ready” mode
•“Auto start” mode
•Weigh every batch
options
•Change recipe
without stopping
Report Setup
•Blender number
•“Auto print” option
•“Auto clear” option
•“Auto interval” option
•Auto start time
Calibration
•Scale Calibration
•Direct Scale Readout
•Feeder Calibration
Mixer & Dump Setup
•Mixing time
•Remix time
•Dump time
•Dump delay
•Dump cycles
•Mixer dump time
•Time/continuous mixing
option
•Continue/stop running on
Mixer Failure
Display Config
•View software version
•Set Time/Date
•Set Red Lion IP Address
•Set Screen Brightness
Units
•
Blender data units (lbs/kg)
•Target v. actual data units
(lbs/kg)
Alarm Log
•
View or clear alarm log
Alarm Setup
•“Stop/Continue”
when out of material
•“Alarm/No Alarm”
when out of material
•“Alarm Silence”
delay
•Accept recipe alarm
enable/disable
•Missing ingredient
compensation option
•Low Levels Treated
as Alarm Only or Out
of Material
Network Setup
•IP Address
•Subnet Mask
•Send Config to ENI
Module
•Enable Ethernet
Configurator
•Modbus Plus
Disabled
User Interface Lock
•Lock the user interface to
prevent others from making
changes or viewing the
blender
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Blender Calibration
The load cells on the blender are FACTORY CALIBRATED. Since the load cells can be
subject to shock loading during shipping, moving, etc., we recommend that they be
recalibrated.
The load cells monitor the weight of each ingredient added to the blender weigh hopper.
Since load cells are reading the actual material weight that is metered by the feeders, the
proper calibration of these load cells is essential for the correct operation of the blender.
The load cells should be checked once a month with a calibration weight and if
necessary recalibrated to ensure that they have not been damaged in the normal routine
of removing and replacing the weigh hopper for cleaning, color changes, etc.
The calibration of each load cell is accomplished by using two reference 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 used in the load cell calibration procedure is a known amount of
weight for the weigh hopper. A calibration weight is provided with all Batch blending
systems. The calibration weight is stamped with its actual weight on top. If this is not
available, any object with a known weight accurate +/- 0.01 lbs. will suffice. (The weight
should be as close as possible to the maximum batch size you plan to run.) The weight will
be in pounds, unless the blender is provided for metric operation. In the case of a metric
blender display, the weight to be used is calibrated in kilograms.
Given the two weight points on the load cell scale, the controller should 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 has a span accuracy of 0.02%.
The maximum capacity of each load cell is clearly marked on top of the load cell. This value
will be indicated in kilograms (1 kg = 2.2 lbs.).
• The weight scale on a new blender comes pre-calibrated, but it is
recommended to periodically check the calibration to ensure that the
reported inventory levels are accurate.
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Verify Weigh Hopper (Load Cell) Calibration
Verifying Calibration (Recommended on a periodic basis to ensure accuracy)
1. The blender must be stopped before this can be done.
2. From the Setup Menu touch “Calibration” and then “Direct Scale Readout”.
3. Remove the weigh hopper.
4. Locate the weight display for each of the two load cells. Write down the displayed
value.
5. Add the calibration weight to each load cell mounting bracket and write down the
value displayed in “weight”, as in step 4.
6. Subtract the values recorded in step 4 from step 5. This is the measured weight. If
the measured weight is within a 0.003 pounds of the weight stamped on the
calibration weight, then you are within spec. If not, follow the steps above to
calibrate the blender. (If your blender is frequently out of calibration, verify the
operator is being cautious removing the weigh hopper during clean out.)
7. Press “X” until you have reached the Recipe screen.
Weight for each loadcell
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Weigh Hopper (Load Cell) Calibration
(Recommended only if the calibration is out of spec)
1. The blender must be stopped before this can be done.
2. From the Setup Menu touch “Calibration” and then “Scale Calibration”.
3. Enter in the scale calibration weight value stamped on the side of the weight.
4. The controller will prompt you to remove the weight hopper and press OK.
5. After touching OK, the controller will display “PLEASE WAIT...”
6. Next, the controller will ask you to hang the calibration weight on the right loadcell
bracket (loadcell A) and press OK.
7. The controller will ask you to hang the calibration weight on the left loadcell bracket
(loadcell B) and press OK. (Does not apply to the BD-150)
8. Finally, the controller will ask you to replace the weigh hopper in the blender and
press OK to complete the calibration.
9. The controller will verify that the calibration was done correctly by showing
“Calibration Successful.”
10. Press “X” until you have reached the Recipe screen.
Follow Instructions
Enter in the
Calibration Weight
Current Loadcell Bits
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Feeder Calibration (AF & RAM Components)
Feeder calibration should be done on all Auger components prior to start-up. This allows the
blender to configure the parameters which will best suit the auger size and gearbox ratio of
the feeder. To perform a feeder calibration, the operator must enter the “Feeder
Calibration” screen (see menu structure), select a feeder number, then touch “Press Here.”
The feeder calibration will start automatically and will notify the operator when complete. If
the operator so desires, they can repeat the process by entering in a new feeder number and
touching the “Press Here” button.
If the blender does not see enough weight gain during the calibration process or if the weigh
hopper reaches maximum weight, then an error is given and the calibration is a failure.
Another useful feature on the “Feeder Calibration” screen is the ability to manually enter in
the “weight per second” values. This increases the blender learning process and the values
can be recorded for future blending.
Alarm Setup
This screen allows the operator to configure the alarm settings for each individual feeder. It
Follow Instructions
Pick a Hopper and
Follow instructions
Stored Feed
Calibration
values
Number of
batches to allow
blender to
stabilize before
alarm
% deviation of
last 3 measured
feeder
calibrations
% of batch size for target
weight during manual
feeder calibration
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can configure whether a feeder will retry during the metering of a batch, and enable or disable
the “Out of Material” alarm for any feeder. If the alarm flag is set to “Retry”, the blender will
not continue until it has metered the correct amount of material. It continuously retries
metering the ingredient until the target is satisfied. It will retry forever under this condition.
The optional low level proximity switches have their own separate alarm. The alarm will
sound, but does not stop the blender unless the low levels are configured as “Treat as Out of
Material”.
1. From the Setup Menu touch “Alarm Setup.”
2. Making changes to the Retry/Alarm settings only affect the recipe after accepted by
touching the accept recipe icon and being loaded after the current batch is complete.
If you want to stop the current batch without waiting for it to complete you must hit
the “abort” icon.
3. Press the “X” key at the bottom to exit this screen.
Enabling this will cause the
alarm light to flash whenever the
“accept recipe” icon is visible
Retry until Target is satisfied or
continue with other ingredients
even if not satisfied
Alarm on Out of Material
Treat Low Levels as Out of Material
Amount of time Horn will be silenced
When used with a Low Level
sensor, ingredients that are Low
are automatically removed from
the recipe until the Low Level
condition goes away
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Network Setup
The blender IP is the address of this blender on a network. The batch blender is factory set up
with an IP address of 192.168.0.10.
In order to change the values, enter the Setup menu, press the “Network Setup” button and
change the values accordingly. You must touch “Send Ethernet Config to Module” before
the change will take effect. After sending it to the module wait 1 minute to test
communications.
Display IP Address and Setting the Time/Date
The Set Date & Time feature is located in the “Display Config” menu of the Setup Screen.
The time is in Military Time.
The display has it’s own Ethernet port and can be configured by entering in the IP and
touching “set IP”.
Enable/Disable Modbus+ communications module
Select if Ethernet module is configured by PLC or
by a separate server.
Set IP and Subnet
Touch here to Program the Ethernet Module with
settings
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Units
Configure the blender for LBS or KGS.
Mixer and Dump Setup
The settings listed below are set at the factory and typically do not require any change.
1. From Setup touch “Mixer and Dump Setup”.
2. Enter a “Mixing Time”. This is the amount of time to run the mixer after a batch is
dumped into the mixing chamber.
3. Use “Remix Time” to set “Re-mix” off time. If set to a non-zero value the mix cycle
will be ran every “re-mix” seconds while the blender is at high level.
4. Use “Dump Time” to set the amount of time the weigh hopper will open while
dumping. This should not be set too long or short.
5. Use “Dump Delay” line for the optional dump delay setting. This is the amount of
time to start the mixer prior to dumping material into the mixing chamber. Set to “0”
to disable this feature.
6. Use “Dump Cycles” to enter the number of times that material will be dumped from
the weigh hopper. This allows the dump valve to open and shut repeatedly when the
weigh hopper is empty to shake lose any sticking material. If this feature is set to “1”
then the batch will dump normally. Normally this is not needed.
7. Use “Mixer Dump Time” to enter the amount of time the mixer knife gate will open
to allow material to exit the mixer. The mixer will also run to assist during this time.
8. Press “X” to return to the “Setup” screen.
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3-6 Initial Startup
The operator can start the blender by touching on the Recipe Page.
The switch will show when running. If the operator selects “Stop Blender” then the
current batch in progress is first finished and then the blender will stop making new batches.
To immediately stop the blender, the operator can touch on the Recipe Page. This will
cause the blender to stop making the current batch immediately. If the blender is stopped in
this method then the current batch will not be completed properly.
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Chapter 4: Operation
4-1 Start-up
General Operation
The general operation of the Batch 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.
Once the batch blending system is powered on, the unit will display the recipe screen (the
recipe format should be in “EZ Recipe” mode). Pressing the highlighted box on the feeder
number, the operator can enter a valid recipe or use a previously stored recipe from the recipe
book.
1. The blender is started by turning system on or material dropping below level switch
in mix chamber.
2. Metering gates are opened (or auger motors are turned on) to meter material into the
weigh hopper in the programmed order.
3. Each component is weighed, then the batch is dumped into the mix chamber
(provided the mixer “High level” switch is not covered).
4. The material is mixed in the mix chamber and flows into the processing machine.
5. The optional slide gate below the mixer may control the flow of material to the
molding machine or extruder.
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Quick Start Procedure
New Recipes
1. Verify the weigh hopper calibration before running the blender (page 47)
2. Ensure that all ingredient supply hoppers to be used are filled with material. Virgin
material should be loaded into hopper #1 and regrind into hopper #3.
3. Enter the recipe menu on the touch screen by turning on the touch screen controller
(It will automatically default to this screen), and enter the blend recipe desired
following the steps listed below:
a. Touch the hopper and enter a new value (0 to 999.99), then hit the green arrow.
b. After you have entering all values push the “Accept New Recipe” icon
Existing Recipes
The operator can load a previously stored recipe from the Recipe Book. The Recipe book
also allows the operators to save the current running recipe. This can be done by performing
the following steps:
1. Touch the Recipe Book icon located on the Recipe Screen.
2. Select a stored recipe by changing the number next to “Recipe #”
3. Touch the “load recipe” icon
4. Touch the “accept new recipe” icon
To edit/save a recipe to the Recipe Book:
1. Go to the Recipe Book by touching the Recipe Book icon.
2. Select a stored recipe by changing the number next to “Recipe #”.
3. Make desired changes to the stored recipe.
4. Touch the “save” icon and wait for it to disappear.
• Hopper #3 on some models is equipped with an oversized square gate to
assist in the feeding of the regrind material.
• The blender only shows the “accept new recipe” icon if the recipe is valid.
• Recipes can also be changed while the blender is running. The new accepted
recipe is loaded at the beginning of the next batch. This allows the operator
to modify the new recipe without affecting the blender until they hit the
“Accept New Recipe” button.
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4-2 Operation Procedures
The objective of this section is to familiarize the reader with the Slide Gate blender recipe
menus, run mode operation, run mode menus and displays. Upon the completion of this
section, the reader will be familiar with the recipes and run mode displays that are available
on one blender, including the recipe book and recipe storage facilities. Other items covered in
this section are optional printer functions and report generation capabilities of the Batch
blending system.
Topics covered in this section are:
• General Operation
• Recipe Menu
• Recipe Book
• Cleanout Mode
• Inventory Page
• Inventory Shutdown Event
• Recipe Formats
• Optional Printer Menu
All personnel operating the Batch blending system should read this section of the manual
before operating the blending system.
Operator Displays
The batch 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.
BLN1-600A Chapter 4: Operation 57 of 116
Entering a Recipe
REQUIREMENTS FOR A VALID RECIPE
EZ Mode
Regrind hopper cannot be over 100%.
Multiple Virgin hoppers must total 100%.
Percentage Mode
Recipe Total must add to 100%.
Parts Mode
All entries are valid.
Touch to change
recipe value
After typing in new
value touch here to
accept
Touch here to Cancel
Entry
Touch here to Accept
the new recipe
Touch here to Undo
recipe change
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Recipe Book
The blender comes standard with a built in recipe book that holds 100 recipes. These recipes
are stored and synchronized with the displays CompactFlash card. You can remove the card
and open the recipes.csv file using Excel. This file has a header row that explains each field.
You can edit the entire recipe book from your computer and then return this CompactFlash to
your blender to synchronize it with the blender’s recipe book. The card must then remain
installed. This would allow you to copy the same recipe books to all of your blenders. It is
also possible to simply edit the stored recipes from the recipe book on each blender. If you
have purchased the USB Jump Drive option then you can place the recipes.csv file you have
modified onto any USB Jump Drive. Then that drive can be inserted into each blender and
the recipe book on each blender will automatically be updated. This is the easiest way to
perform a mass edit of all your blender’s recipe book.
REQUIREMENTS FOR A VALID RECIPE
EZ Mode
Regrind hopper cannot be over 100%.
Multiple Virgin hoppers must total 100%.
Percentage Mode
Recipe Total must add to 100%.
Parts Mode
All entries are valid.
Touch here to bring
up the Recipe Book
Modify any recipe
value in the stored
recipe
Touch here to close
the Recipe Book
without loading a
selected recipe
Load the selected
recipe into the
blender
Touch arrows to
increase/decrease
recipe number. You
can also enter in the
recipe number if you
know it.
If you’ve modified a
recipe the SAVE icon
will appear. Touch to
save changes before
leaving the recipe
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Cleanout Mode
3
Touch here if blender
is stopped
Touch hopper icon to
open/close feeder
Touch weigh hopper
icon to open/close
Touch mixer icon to
start/stop
Touch knife gate icon
to open/close
Touch here to Cancel
Cleanout mode
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Inventory Page
Touch here to bring
up the Inventory Page
Material weight that
has been weighed and
dispensed through the
weigh hopper
Print Inventory
Magnified TOTAL
INVENTORY page
for long distance
viewing on OI units
Clear Inventory. You
will have to enter
your password and
confirm.
Touch here to close
the Inventory Page
Batches counted in
Total Inventory
Max Blender rate
with current recipe
Average Batch time
in seconds
Consumption rate of
process
Touch here to close
Magnified View
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Recipe Entry Formats
The Batch blending system contains several operator friendly recipe menus. This section of
the manual lists these recipe menus:
• Recipe Page (Start/Setup)
• Recipe Book Page
• Recipe Format
Upon Start Up, the blender controller will default to the “Recipe” 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: “EZ Recipe” Mode, Percentage Mode or Parts Mode. (“EZ Recipe”
mode is the default setting preset at the factory.)
Recipe Format Menu:
• “EZ Recipe”, Percentage or Parts
• Metering Order (Always make sure all 8 hoppers are entered)
• Batch Size (only use batch sizes appropriate for your blender, too small will cause
inaccurate blending)
• Inventory Shutdown (used to shut the blender down after making a certain amount)
• “Batch ready” mode (blender will hold a completed batch in the weigh hopper)
• Weigh every batch options (determines if every batch is weighed)
• Change recipe without Stopping (if set to “Stop Blender before Changing Recipe” then
the operator does not need to touch the “accept recipe” icon after editing the recipe).
The drawback is that the recipe cannot be changed on the fly.
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 manufacturer’s 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.). The following Recipe
Modes are described on the next few pages.
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“EZ Recipe” Mode (Most common in injection molding)
The “EZ Recipe” menu structure allows recipes to be entered and adjusted by touching the
buttons on the panel face (for 1 to 6 components). In this mode, hopper #1 is configured as
virgin, hopper #3 is configured as regrind, and the others are configured as additives, i.e.
color. The operator enters in the percentage of regrind and additives, and the virgin
percentage is automatically calculated. The regrind percentage represents a percentage of the
total batch, and the additives are based on a percentage of the virgin weight. This is useful
because the percentage of regrind can be changed without affecting the ratio of color or
additive to the virgin weight. Each percentage can be up to 100%, but not greater. The virgin
percentage is automatically calculated by 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.
• The #1 hopper (“NAT” - Virgin Material) recipe ingredient will not be
shown on the recipe setup menu.
• ADD (Additive) designations will weigh the ingredient as a percentage of
natural material only.
• RGD (Regrind) designations will weigh the ingredient as a percentage of the
total batch. (It is assumed the regrind has been generated from pre-blended
production and already contains the same color and/or additives.)
• Virgin material must be loaded into hopper #1 and regrind into hopper #3.
• Component #3 is designed to handle regrind and most models come
equipped with a larger, square gate to reduce the likelihood of bridging. If
regrind is being used, it should always be run through component #3. If you
don’t have regrind, another major ingredient can be run through
component #3.
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Figure 36: Example Calculations of a 5-component blend in “EZ Recipe” mode
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.
Total available: 100.00%
Regrind: 30.00%
Balance: 70.00%
Virgin + Additive 1 + Additive 2 + Additive 3 = 70.00%
Virgin + (5% of virgin) + (2% of virgin) + (1% of virgin) = 70.00%
Virgin + (5/100 x virgin) + (2/100 x virgin) + (1/100 x virgin) = 70/100
100 virgin + 5 virgin + 2 virgin + 1 virgin = 70
108 virgin = 70
Virgin = 70/108 = 64.81%
Virgin = 64.81% of batch
Additive1 = 5% of 64.81% = 3.24% of batch (5% of virgin)
Regrind = 30% of batch
Additive2 = 2% of 64.81% = 1.30% of batch (2% of virgin)
Additive3 = 1% of 64.81% = 0.65% of batch (1% of virgin)
Virgin + Additive 1 + Additive 2 + Additive 3 + Regrind = 100%
64.81% + 3.24% + 1.30% + 0.65% + 30.00% = 100%
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“Percentage” Mode (Most common in extrusion and blow molding)
Extrusion processing often requires recipes in percentage format, especially if regrind is not
involved, i.e. blown or cast film.
In this mode, operators enter in values for each hopper up to 100%. The total of all the
hoppers must equal 100%. If they don’t, an error message appears on the Recipe screen and
prevents the recipe from being accepted. All hoppers are a percentage of the total batch size.
“Parts” Mode (Often used in Compounding Applications)
The “Parts” recipe entry mode lets the operator enter in values based on a parts ratio rather
than a percentage. Each entry can be up to 999.99 and the total of all hoppers does not have
to be 100. After all values are entered, the total parts are calculated. The individual hopper
target is then calculated based on each hopper’s entered parts. These parts represent ratios of
the total batch. For instance: Hop 1=300 parts, Hop 2=100 parts, Hop 3=10 parts, Hop 4=5
parts. This would mean that if the batch was divided into 415 parts, then Hop 1 would make
up 300 of those parts, Hop 2 would make up 100, Hop 3 10 parts, and Hop 4 5 parts.
Figure 37: Example Calculations of a 4-component blend in “Parts” mode
Feeder Tag
Preset Part
Calculated Weight
(Ratio Control)
Virgin
#1
7,200
7,200/10,000
Regrind
#2
2,000
2,000/10,000
Color
#3
500
500/10,000
Additive
#4
300
300/10,000
Total:
10,000
Switching Modes
Recipe Modes can be switched while the blender is making a batch. At any time the operator
can switch the recipe entry mode without affecting the current batch being made. The recipe
mode is part of the “New Recipe” and is separate from the running recipe.
Recipe Setup
Metering Order
The Batch blender allows the operator to set the ingredient metering order when making a
batch. In order to access the metering order menu, enter the Setup menu and press the
“Recipe Format” button (refer to the menu structure on page 39). Once in the “Recipe
Format” menu, view “Metering Order.” This display will indicate the current order in which
the ingredients are metered. A Metering Order of “12345678” means that the blender will
feed hopper 1 first and hopper 8 last.
In order to change the metering order, simply press the “Metering Order” button. In the next
screen, the operator must select a value from 1 to 87654321 and press the green enter key.
Once the desired metering order is displayed, simply press the “X” exit. If the order is
changed, then you will need to touch “Accept New Recipe” icon on the Recipe Screen
before the change takes effect.
• All ingredients are weighed as a percentage of the total batch.
• The preset part will be divided by the total of all parts, with each part
representing the calculated weight for ratio control.
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This order can be changed while the blender is making a batch without affecting the current
running batch.
Batch Size
The Batch blending system is a gravimetric batching system. The blender will weigh a
preprogrammed batch of material each cycle. This batch size is determined by the blender’s
weigh hopper size, the current recipe, and the bulk density of the ingredients.
Because the blending systems must handle a wide variety of materials, with varying bulk
densities, the actual amount of weight of material the weigh hopper will hold can vary
dramatically from application to application.
This feature allows the operator to change the size of the batch to be made. A value will need
to be entered between 0.5 to 99.9. This can also be changed while making a batch without
affecting the current running batch. If the size is changed then you will need to touch
“Accept New Recipe” on the Recipe screen before the change takes place. This feature
allows stored recipes with different batch sizes to easily be loaded without the operator
having to reconfigure the blender every time they want to load a stored recipe.
The weigh hopper size selected should be one that approaches the maximum capacity of the
load cells without over-filling the weigh hopper. During the initial setup of each blender, the
weigh hopper size setting should be checked to ensure that the weigh hopper is not overfilling
due to a large percentage of light weight regrind, etc. The batch size will vary from model to
model. The bulk density of the material being blended will also affect the batch size.
Figure 38: Typical Batch Sizes
Blender
Batch Size (lbs.)
150
1.5
500
4.0
900
8.0
2500
25.0
4000
35.0
6000
45.0
Inventory Shutdown
In many applications, the user of the Batch blending system produces large runs of blended
material on the same recipe during production. An example may be a 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, the manufacturer has provided a means to
automatically stop the blending system when the blended material has reached a preset total
blended weight. This is known as Inventory Shutdown.
When the Inventory Shutdown value is reached, the blender will finish the current batch of
material. It will then stop and display to the operator that the inventory value has been
reached. Additionally, it will flash an alarm and wait for operator attention. An example of
this screen is shown below:
• All feeders must be in the metering order. If you enter an invalid metering
order then the blender will default back to its original setting of 12345678
• If running a high percentage of lighter density regrind, set the batch size so
that the mixer does not overfill, preventing the weigh hopper from fully
dumping when operating in “Batch Ready Mode”.
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Typical Inventory Shutdown User Prompt Operator Screen
To enable this feature, simply enter a desired shutdown weight value (from 1 to 999999999)
into the Inventory Shutdown display line of the Recipe Format screen, under the Setup menu.
This feature can be configured while the blender is making a batch. If the Inventory
Shutdown is changed, then you will need to touch “Accept New Recipe” on the Recipe
screen before the change can take place. This allows stored recipes with different Inventory
Shutdown settings to easily be loaded without the operator having to reconfigure the blender
every time they want to load a stored recipe.
To disable this feature, simply enter a zero (0) value.
Batch Ready Mode
This enables the blender to have a batch already made in the weigh hopper while the mixer is
full. Enabling this feature dramatically increases the maximum achievable blender rate.
Auto Start Feature
By enabling this feature, the blender accurately finishes a batch that was interrupted by loss
of blender power. This option starts the blender if it was running prior to power loss. It does
not turn on the blender if it was previously stopped prior to power loss.
Weigh Every Other Batch Feature
This setting allows the operator to only weigh selected batches. The operator can choose
from the following: “Weigh Every Batch”, “Weigh Every Other Batch”, “Weigh Every Third
Batch”, “Weigh Every Fourth Batch”, “Weigh Every Fifth Batch”, and “Never Weigh”. If a
batch is timed instead of weighed then all components run concurrently instead of one at a
time. This dramatically increases the maximum blender rate, but introduces error into the
timed batches. Because the ingredients are not weighed, error is introduced into the
Inventory Totals. Each timed batch is assumed to be “perfect” and these “perfect” dispensed
amounts are added to the Inventory Totals.
Touch here to close
this page and go back
to the recipe page
Touch here after
you’ve changed the
Gaylord box to restart
the weight counter
and the blender. This
does not clear the
inventory shown on
the inventory page.
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Every Batch:
This mode of operation weighs every component of every batch that is metered by the
Batch blending system.
Every Other Batch:
First batch weighed. Second batch is metered based on the metering times of the first
batch.
Every Third Batch:
First batch weighed. Second and third batches are metered based on the metering times
of the first batch.
Every Fourth Batch:
First batch weighed. Second, third, and fourth batches are metered based on the metering
times of the first batch.
Every Fifth Batch:
First batch weighed. Second, third, fourth, and fifth batches are metered based on the
metering times of the first batch.
Never Weigh:
Metering is based on Feed Calibration values only. Loadcells are not used. This is only
used if you have a failed loadcell.
• Not weighing every batch sacrifices blender weighing accuracy, but
increases the blender’s maximum rate.
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Mixer and Dump Setup
Mixer Options
Press the “Timed/Continuous Mixing” key (In the top right hand corner) when in “Mixer and
Dump Setup” screen to set the following options:
Timed Mixing Option
This mode of operation turns the mixer on only during dumping and during the re-mix
time set into the control to jog the mixer during high level mixer operation.
Continuous Mixing Option
This mode of operation turns the mixer on after initial startup and will continue to run
continuously, unless the remix time is set to jog the mixer during high level mixer
operation. This option is used for sticky materials that tend to bridge and block off the
mixer discharge to the processing machine.
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 Batch 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. After entering
the Setup menu, the user must select “Mixer and Dump Setup.”
Figure 40: Typical Mixer and Dump Setup Operator Screen
Selecting “Mixing Time” from the “Mixer and Dump Setup” menu will allow the operator to
view the current time setting for the mix timer and to adjust it as needed.
Re-Mix Timer
In some applications, the Batch blender will require the use of the re-mix timer. Some
materials tend to separate if they are mixed too long. This is possible when a processing
machine is running at a rate significantly below the capacity of the blender.
With external vibration, the heavier pellets will tend to flow to the bottom of the mix chamber
before the lighter material. This will occur even though the mixer is in a static mode. By re-
mixing occasionally, this situation will be prevented.
The re-mix timer will start another mixing cycle if the blender has been idling long enough
for the re-mix timer to time out. The re-mix timer may be set on the “Mixer and Dump Setup”
screen from 1 to 999 seconds. Setting the re-mix timer to zero will disable this function.
If the re-mix timer is disabled, the controller will run only a single, timed mix cycle after each
dump of the weigh hopper.
BLN1-600A Chapter 4: Operation 69 of 116
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.
Weigh Hopper Dump Time
The weigh hopper dump time is the amount of time the weigh hopper’s dump valve remains
open to allow weighed material to exit the hopper and enter the mixer.
To view and change the current weigh hopper dump time settings, enter the Setup menu and
select the “Mixer and Dump Setup” screen. Press the field next to “Dump Time” to set the
operation of the Dump Valve.
The timer should be set to close the dump valve shortly after the material has totally dumped
from the weigh hopper. This time can vary due to material flow characteristics, and the size
of the batch that is programmed into the blender control. Experimentation with this setting
can allow the operator to determine the best cycle for the material being weighed.
Weigh Hopper Dump Delay Time
The dump delay time is the amount of time from the end of metering the last ingredient until
the start of the actual dump cycle. The start of the dump cycle is marked by the opening of
the weigh hopper dump valve. This value has a range from 1 second to 999 seconds. To view
and change the current dump delay time, enter the Setup Menu, select “Mixer and Dump
Setup” screen, and then select “Dump Delay”.
The default time is factory set at zero seconds. This delay time is used to start the mixer prior
to dumping the material from the weigh hopper into the mix chamber of the blender.
Weigh Hopper Dump Cycle
The dump cycle allows the weigh hopper dump valve to cycle, or open and close, a number
of times prior to commencing with the next batch cycle. The setting allows from 1 to 9 dump
cycles between batches (open and closed cycles).
The normal and default factory setting is 1, meaning the weigh hopper dump valve will open
at the end of the weighed batch and close after the batch is discharged into the mixer.
Setting the dump cycle to more than one cycle may be useful when blending high static, dusty
material or those that have sticky tendencies. This will cycle the dump valve open and closed
to allow any material that may cling to the dump valve.
To enter the dump cycle menu, first enter the Setup menu by pressing the Manufacturer’s
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” menu. Press
the “Dump Cycle” key to enter a dump cycle value and press enter. Please refer to the menu
structure tree shown in section 3-5.
Mixer Dump Time
The mixer dump time is the amount of time the knife gate below mixer’s valve remains open
to allow blended material to exit the blender.
To view and change the current mixer dump time settings, enter the Setup menu and select
the “Mixer and Dump Setup” screen. Press the field next to “Mixer Dump Time” to set the
operation of the Dump Valve.
The timer should be set to close the dump valve shortly after all material has been emptied
from the mix chamber. This time can vary due to material flow characteristics, and the size
of the batch that is programmed into the blender control. Experimentation with this setting
can allow the operator to determine the best cycle for the material being mixed.
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Continue/Stop Running if Mixer Fails
If the blender is configured with the “Mixer Failure Detection” option then the user can select
if he wants the blender to alarm only or stop if the mixer movement is not detected during
mixing.
Alarm Messages
An alarm message will be shown if any alarm condition occurs. A message will pop up on
the screen until the alarm condition is resolved. During an alarm condition, not only will a
visual alarm show up on the screen but also an audible alarm will sound. The operator can
press “OK” on this pop-up to hide the screen temporarily, but if the alarm condition is still
unresolved, then the message and horn will reappear after a short delay.
The blender will log when the alarm event occurred and when the condition went away.
The following is a list of all alarm names and descriptions:
Hopper 1-8 Out of Material: This alarm indicates that a hopper is out of material and
signals the operator that they should check the resin system.
Hopper 1-8 Low Level: This alarm indicates that a hopper with a low level prox sensor is
low.
Surge Hopper Empty: This alarm indicates that the surge hopper sensor is sensing a low
level. This can be any surge hopper and not necessarily related to the blender. It is a
customer specified alarm input.
Mixer Failure: This alarm indicates that mixer movement was not detected when it was
suppose to be. This is only available if the Optional “Mixer Failure” feature has been added
to the blender.
Unable to Make Rate: This alarm indicates that the blender has not hit high level in an
appropriate amount of time.
Hopper 1-8 Unstable Alarm: This alarm indicates that a hopper has not stabilized. This is
determined by examining the last 3 feed calibration measurements while the blender is
running. If the 3 measurements are within a set deviation of each other than the hopper is
“stable” and these measurements are used to average the feed calibration value. If not then a
counter is increased every batch and the feed calibration value remains unchanged. After a
set amount of batches that are not “stable” then an alarm is given.
Hopper 1-8 Overfeed Alarm: This alarm indicates that a hopper has put too much into the
current batch.
Max Hopper Weight Exceeded, check batch size: This alarm indicates that the weight in
the weigh hopper has exceeded the maximum allowed weight. This alarm can happen if the
operator changes material density and does not perform a feeder calibration, but will usually
be automatically fixed after the first batch. As long as this alarm doesn’t continue to
reappear, then the operator should not be concerned. If the alarm continues to occur, then the
operator should have maintenance check the blender.
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. This alarm is most commonly caused by a build up of sticky material in the weigh
hopper and can be corrected by simply cleaning out the weigh hopper. If this does not correct
the problem, then the scale calibration should be checked by maintenance.
BLN1-600A Chapter 4: Operation 71 of 116
Power Interruption while metering a Batch: This alarm indicates that the blender’s power
was turned off while the blender was making a batch. The batch accuracy would have been
compromised since it did not finish the batch in progress.
PLC Battery Low: PLC battery is low and may cause the blender to lose both the program
and the blender configuration. Notify Maintenance immediately.
PLC Module Loaded: This alarm occurs after a software upgrade to the PLC. The alarm
instructs you to turn off power to the blender, remove the Memory Module, turn on power,
and then reconfigure the blender parameters.
Inventory Cleared: This is only logged in the Alarm Log and does not cause a pop-up
message or audible alarm. Each time the inventory is cleared, the time and date are logged to
the Alarm Log. An alarm will sound and a screen will pop up when Auto. Inventory
Shutdown has been reached.
E-Stop Screen: The blender is equipped with an System-stop switch that removes the power
from all mechanical outputs. The System-stop Screen appears along with an audible alarm
whenever the System-stop is activated. The operator can not access any screens until
System-stop is deactivated. The Panel View will then put the screen back to the display that
the operator was on prior to hitting the System-stop. The System-stop does not provide a
category 0 or 1 stop. It is recommended that the System-stop be moved closer to the power
input so as to disconnect all power when the System-stop is pushed.
BLENDING MODE SEQUENCE
Once the operator initiates the run mode of operation, the blending system controller will
begin monitoring the mixer high-level switch. Nothing will happen until the mixer high-level
switch is uncovered. This tells the controller that the mixing chamber is capable of holding
another batch of material.
Once the mixer high-level switch is uncovered, and the weigh hopper has dumped, the system
will meter the ingredients from the supply hoppers, through the metering units, into the weigh
hopper. Each component will be metered individually to allow accurate weighing of the
material.
Each component is metered in the order specified by the “Metering Order” setup. See the
Installation & Setup chapter for further details.
Once the final ingredient specified in the recipe has been metered into the weigh hopper, the
controller will take a final weight reading of the weigh hopper. This will start the “Dump
Delay” timer. (See Page 58). Once the dump delay timer has timed out, the controller will
activate the weigh hopper dump valve, initiating the weigh hopper dump cycle.
The open weigh hopper dump door will allow the material to drop into 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. (Unless the Re-Mix timer is set to a value other than 0 and times
out to restart the mixer to run for another mix cycle.)
The level sensor is located on the back wall of the mixer chamber. If the sensor is covered
with material, the indicator light on the back of the sensor will be lit.
• Before starting Batch blending systems, each ingredient hopper in the
current recipe must contain material! Virgin material must be loaded in
hopper #1 and hopper #3 should only be used for regrind!!
BLN1-600A Chapter 4: Operation 72 of 116
Once this sensor is uncovered, the indicator lamp on the back of the level sensor will go out.
This level sensor must be uncovered for approximately 1 - 2 seconds to indicate to the
controller that there is room in the mixing section to accept a batch of material.
When the controller has determined that the mixer is ready for an additional batch of
material, the controller will begin metering material into the weigh hopper assembly.
Printer Features
The Batch blending system may be equipped with a printer, so a printer menu is available to
the operator. This menu is displayed in the “Report Setup” area of the Setup screen. The
printer menu is accessed by pressing “Report Setup” from the Setup menu.
Figure 50: Typical Report Setup Operator Screen
The blender can be configured to automatically print and clear inventory on a selected
interval. To automatically print or clear reports perform the following:
1. Enter in the Report Interval in hours (1-24).
2. Enter in the Report Start Hour (0-23, 0 is midnight).
3. Enable “Auto Print Inventory” and “Auto Clear Inventory.”
The user can select to only print the inventory on an interval if so desired by not enabling the
“Auto Clear Inventory” feature. The user should also enter in the blender number which will
identify the blender that the printout came from.
The printed inventory might not match the percentage shown, as the percentage shown is the
actual blender percentage running the current recipe. The inventory, depending on when it
was manually cleared, may or may not reflect the current recipe inventory. Some customers
like to run an accumulated inventory on ingredients coming from silos, etc., even though
several different recipes have been run on the blender. Others like to clear the inventory every
time the recipe is changed. The blender gives the operator the choice of either method.
The Report Setup Printer Menu contains four (4) options:
• Batch Interval
• Print Inventory
• Clear Inventory
• Display Time & Date
Batch Interval or Timed Interval Printout
Blender Number will
be printed on Report
Report Interval in
hours (1-24)
Report Start Hour (0
to 23, 0 is midnight)
Enable/Disable the
Autoprint & Auto
Clear Inventory
BLN1-600A Chapter 4: Operation 73 of 116
The Batch Interval item under the Recipe menu works in conjunction with the Auto Print
Interval to set the number of batches between printouts or on a timed interval between
printouts.
Timed Printout
When entering the Report Setup menu, the operator will have to decide whether the printout
should be timed and by the number of batches between each printout. The operator will have
to toggle between the “Recipe Format” and the “Report Setup” screens to configure the
settings properly.
If you want to print out on a time format, press the button next to the “Auto Print/Clear
Interval” key. The screen will then prompt the operator to set the time interval in hours (1 to
24).
If you want to change the hours between printouts, press the “Auto Print/Clear Interval” key
again to change the value to the desired time.
The operator will then need to program in when they want to begin the timed printouts.
Simply select the time (0-23, {midnight =0} on a 24-hour clock) and press the “Done” key to
retain the current settings in the “Report Setup” screen.
Batch Printout
The target vs actual weight data for every batch can also be printed. See “Advanced Weight
Options” to turn this on/off. This feature uses an excessive amount of paper and should only
be used for trouble shooting.
Print Inventory
The print inventory menu item is used to produce on demand, inventory printouts. Before
selecting this item, be sure that the printer is properly connected and ready. This function will
generate an inventory printout with the current date and time information.
Display Time and Date
The display Time and Date item in the upper right corner of the “Report Setup” menu is used
to verify the current time and date information.
Color Changes
The color change procedure is meant for use with the basic Batch Blender. This procedure
assumes that the color component of the blend is in an additive ingredient hopper (#2, #4, #5,
or #6).
1. Disable and clean any color loading equipment. Please refer to the loading equipment
manual for any clean up recommendations.
2. Using the blender “Abort” or “Push to Start or Stop” key, put the blender in stop
mode. After the cycle has completed, switch “OFF” the main power switch and
unplug the blender power supply.
3. Open the upper mixer access door. This shuts off air to the blender circuit by
deactivating the master air valve. Then unplug the quick disconnect from the air
• The blender must be stopped to make color changes. The processing
machine can operate on virgin material only during this procedure with an
optional quick color change bypass tube that can be installed to bypass the
blender. Contact the factory for details.
BLN1-600A Chapter 4: Operation 74 of 116
supply hose to the blender to further ensure that no air pressure is supplied to the
blender.
Always unplug the main power cord.
Always disconnect the air supply to the blender.
Prior to performing any operations inside any access areas of the blende
where there are moving parts.
6. Remove the weigh hopper by unplugging the air line disconnect fitting, holding the
dump door closed, lifting the hopper to clear the load cell brackets, and gently pulling
the weigh hopper out of the blender.
To reduce the chance for damage to delicate load cells, use care when
lifting the weigh hopper off load cell locating tabs and when reinstalling
the weigh hopper on load cell brackets.
7. If you want to catch the color, use a small plastic pail or chute to collect the material
from the slide gate assembly. Reach up inside the blender to the color slide gate and
push it open. At this point, there should be no air pressure on the blender, and the
slide gate should move easily. Drain the color out in the bucket. Blend and Reclaim
normally provides a JIT (Just in time) approach to the minor ingredients, so that a
minimum amount of material is held in the blender so that color changes can be made
easily.
8. If any other ingredients need to be changed for the next recipe, simply drain the
larger hoppers with the drain tubes provided on the side of the hoppers. When the
material level is below the drain tube, open the slide gate manually to dump the rest
of the material. If you wish to speed the emptying process, material can be manually
drained out of the slide gate assembly into a dump chute or bucket, while draining
from the drain tube.
9. Using a vacuum cleaner or air hose, clean out all the hoppers that have been emptied.
Always start at the uppermost part of the blender and work downward to prevent dust
and pellets from falling into an already cleaned area.
The auger metering assemblies on Auger blenders can be removed after
the hoppers above them have been drained.
10. Clean the weigh hopper and mixer assemblies on the blender using a vacuum cleaner.
The mixer agitator is removable for cleaning if desired.
11. Reinstall any metering units that were removed from the blender during clean out.
12. Reinstall the weigh hopper using care to center the hopper on the load cells on the
weigh hopper bracket.
13. Load the blender with new material.
14. Restart the unit with the new recipe.
Always disconnect and lockout all electrical power and pneumatic (i.e.
compressed air) sources prior to servicing or cleaning any product,
including all Batch blending systems. Failure to do so may result in
serious injury or death.
BLN1-600A Chapter 4: Operation 75 of 116
4-3 Shut-down
The Slide Gate Gravimetric Blender can be stopped in one of two ways:
1. To immediately stop the blender, the operator can touch “Abort Current
Batch” icon. This will cause the blender to stop making the current batch
immediately. If the blender is stopped in this method then the current batch will not
be completed properly.
2. If the operator desires to complete the current batch of material, then he can
stop the blender using the selector switch icon. The blender will finish the current
batch of material before stopping.
BLN1-600A Chapter 5: Maintenance 76 of 116
Chapter 5: Maintenance
5-1 Preventative Maintenance Schedule
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 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 #
Daily
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Inspect blender for
any loose parts-
tighten them
immediately.
Verify quality of
compressed air
supply.
Verify mixer door is
properly latched.
Every week
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Inspect metering
gates for proper
operation.
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 blender
only If necessary.
Photocopy this page for your maintenance records
BLN1-600A Chapter 5: Maintenance 77 of 116
5-2 Preventative Maintenance
Our 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 – as
required.
• Periodically lubricate slide gate rails.
Always remove plug and disconnect power before servicing blender.
Always read operating manual before operating or servicing blender.
For gear boxes on BD, SGBD, CSG-4000/6000 and RAM units with right angle gear boxes:
• Change oil after initial break-in period of 250 hours of operation and at 2500 hours of
operation or 6 month intervals after break-in period.
• Recommended oil is Mobil SHC 634 Synthetic oil. 5 gal P/N: OIL0041
Part Description
Part Number
Oil Capacity
(Fluid Ounces)
4000/6000 Right
Angle Reducer
51415
13
160.00280.00
11
RAM
51183
4
BLN1-600A Chapter 5: Maintenance 78 of 116
5-3 Corrective Maintenance
Electrical
This section is designed to give the operator an overview of the electrical system that controls
the Batch blending system. Since the blender’s control panel is a self-contained pluggable
item, seldom will a maintenance person be required to enter the control panel. For purposes
of understanding the system, it is advisable that the maintenance personnel be familiar with
not only the internal workings of the control panel, but also with the input and output signals
to the Batch blender.
This section includes the following:
• Internal components of the control panel
• Input signal to the control panel
• Output signals from the control panel
Internal Components of the Control Panel
This section describes the internal components of the Batch blending system control panel. It
is not the intent of this section to completely familiarize the reader with the details on
industrial control panel construction or standards, but simply to familiarize the reader with
the major components inside the control panel.
The customer must supply 120-240/1/60 or 110-220/1/50 voltage via wires L1 & L2 (N).
Please insure that the earth ground connection is properly connected to an established earth
ground.
• “Power on” is indicated by a lighted on/off selector switch.
• “Slide gate below mixer” switch controls position of optional slide gate.
• “Safety Active” light displays status of safety interlock circuit.
• Audible alarm horn alerts operator to blender fault.
• See Installation Packet supplied with unit for complete electrical schematics.
BLN1-600A Chapter 5: Maintenance 79 of 116
Input Signals to Programmable Controller
The Batch blending system has two main input signals that it uses from the blending process:
the mix hopper high level signal and the weigh hopper load cells. This, of course, does not
include the operator touchscreen input.
The mix hopper high level signal is generated by a proximity level sensor located in the right
hand portion of the mixer chamber (viewing from the mixer door).
Load cells require +10 volts DC to operate. This is known as the load cell’s excitation
voltage.
Output Signals from Programmable Controller
The Batch 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. Please refer
back to the wiring diagram. The origin of the weigh hopper dump signal is a PLC output.
The auger motor outputs are driven from a control output from the PLC.
Each blending system includes an auxiliary customer alarm output. This dry contact can be
used to switch a remote alarm signal.
The customer alarm output is provided to actuate or energize a variety of alarm horns,
buzzers, strobe lights, and beacons. These are normally provided by the customer, and
care will have to be exercised not to exceed the maximum current draw (3 amp
maximum). The contacts will close whenever the control detects a fault that will somehow
inhibit the blending system from properly blending the material.
• The customer alarm contact is open if the panel control power is turned off.
• This contact is for use with a customer supplied alarm device as described
above.
• The alarm contact has a maximum load of 3 amps.
BLN1-600A Chapter 6: Troubleshooting 80 of 116
Chapter 6: Troubleshooting
6-1 Introduction
The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal trouble-shooting must be
accomplished with the power off, line fuses removed, and with the machine tagged as out of
service.
The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a ammeter that can measure at least twice the AC and DC current that can be
encountered for the machine. Be sure that the voltmeter has at least minimum impedance of
5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales. Popular combination
meters, VOM and VTVM can be selected to provide the necessary functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
Figure 53: Typical Troubleshooting Problems and Suggested Corrective Actions
Problem
Corrective action
Nothing happens when I push
“Start Blender”
Check to make sure that air is hooked up and the regulator gauge
reads at precisely 60 PSI.
Check that the access door to the mixer is shut properly.
Look on the Recipe Screen. If you see “Mixer Full”, then check
the mixer. If the mixer is not full, then check that the mixer prox
is adjusted properly (small screw on back).
“E-STOP has been Activated”
is shown
Check the E-stop located on the front of the blender panel.
“Interface Locked” icon
is shown
Click “Unlock” and enter in your User Password.
I’ve forgotten my User
Password
Contact the Service Department.
POWER INTERRUPTION
ALARM
Power was lost during a batch. Check your power source unless
you intentionally killed the power during the batch.
PLC Battery Low
Change out the PLC with your spare and reprogram new unit.
Send old PLC back to Manufacturer for repair.
BLN1-600A Chapter 6: Troubleshooting 81 of 116
Problem
Corrective action
PLC Module Loaded
Normal after a software upgrade. Follow on-screen instructions.
Check the input power. Verify that 110 volts (or 220 volts) are
±10%. This voltage must remain constant with all the motors
starting and stopping. Insure that the blender is on a “clean” circuit
that does not have other equipment on it. If the power is known to
be intermittent and have problems, set up the unit to run in
“AutoStart” mode. See the factory setup sheet at the end of this
manual. In this mode, if a short power interruption occurs, the
blender will automatically restart.
Check the power supply. Make sure that it has +5 VDC output to
the CPU board. Adjust to +5 VDC, ±0.1 volt.
Check the display ribbon cable connection to the CPU board and
the display. See the electrical chapter for more information.
Check the contrast adjustment located on the display board.
Check keyboard ribbon cable connections.
Check the CPU board for “lockup”. To do so, reset the CPU board
by cycling the power off and on at the motor control panel.
Weigh hopper occasionally
overfills.
Check batch weight setting in the recipe menu. See the setup
chapter for 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. If
a vacuum receiver has a leaking flapper valve and the supply
hopper is not vented, the blender computer can learn inaccurately
and cause an overfill condition on the next few cycles.
Check the load cell connections to the panel.
Material sticks to the flapper of
the weigh hopper and is not
dumped.
Increase the Dump Cycles setting in Mixer and Dump Setup.
Too much material remains in
the mixer.
Increase the Mixer Dump Time in Mixer and Dump Setup.
The material is not being mixed
thoroughly.
Increase the Mixing Time in Mixer and Dump Setup.
BLN1-600A Chapter 6: Troubleshooting 82 of 116
Problem
Corrective action
Recorded Inventory Totals
don’t match what I’ve actually
used
Check the blender’s scale calibration and verify that the batch
hopper is not overfilling. If the hopper is overfilling, adjust your
batch size. If this is correct, then you are probably not accounting
for material scrap or other items in your process.
Some error can be introduced by not weighing every batch. Check
the Recipe Page.
Max Hopper Weight Exceeded
Alarm continues to re-occur.
Stop the Blender and the Start it again. This causes the blender to
perform an automatic feeder calibration. If this doesn’t fix it, then
manually perform feeder calibrations and retest.
Printer did not print
Check that the printer is a SERIAL printer. If not, then you will
need to either get a SERIAL printer or purchase a SERIAL to
PARALLEL converter.
Check printer communication settings under Panel View Config.
I’m missing an Automatic
Inventory Report
Check that the date and time are set correctly on the Panel View
Config Page.
Blender occasionally dumps an
incorrect batch.
The blender intermittently dumps a batch of material with one or
more of the components incomplete.
Check the recipe information; ensure that both the percentages and
batch size are set properly.
Check the status of the alarm flags & Feeder Setup to ensure that
all of the feeders are set to Retry. In addition, if the blender is
configured for timed batches then this can cause error.
Check supply hopper ventilation to prevent problem associated
with leaky vacuum receiver flappers.
Blender keeps dumping after
mixer is full.
Check the mixer high-level switch sensitivity. When the sensor is
covered by material, the indicator lamp on the back of the switch
should be lit. To adjust the sensitivity, use the small adjustment
screwdriver that was provided with the blender. The adjustment
pot is located on the back of the sensor. Rotate clockwise to
increase the sensitivity (less material in front of the switch to
actuate it). Rotate counter clockwise to decrease the sensitivity
(more material covering the switch).
Check the mixer high-level sensor connection to the control panel.
Blender will not batch with
empty mixer.
Check the mixer high-level switch sensitivity. Fines may have
coated the level switch; it needs readjustment.
Check the proximity switch connection.
Make sure that the recipe is correct.
Check batch size.
BLN1-600A Chapter 6: Troubleshooting 83 of 116
Problem
Corrective action
Mixer won’t shut off and runs
continuously.
Check the Mixer and Dump Setup to see if the mixer is configured
for “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. This is located in the control panel on
the SSR for the mixer motor. If the unit has two (2) power inlets
with a separate power inlet for the mix motor the overload fuse
will be located in the rear junction box on the blender frame.
Check the power source to the blender.
Check the load cell in diagnostics under direct scale readout. Place
a calibration weight on the weigh hopper; determine if the weight
corresponds.
Check the load cells to make sure that a pellet has not jammed
under a load cell.
Check the load cell connections to the control panel
Check the power supply voltage and readjust as necessary as
described earlier.
Out of Material Alarm or Low
Level is displayed, but there is
material in the hopper.
Go to the Manual Control Page and check to see if “Hop Low”
equals “1”. If it does, then adjust the low-level prox until the value
reads “0”.
Ensure that the material hopper is properly vented. If the vacuum
receiver is leaky, then this will cause the problem. To test this, fill
up the hopper and turn the loader off to prevent leaking.
If this isn’t the problem, then increase the “Out of Material Retry
Limit” found under Feed Algorithm Options (see manual).
I’m not getting Out of Material
Alarms
Check the Alarm Flags & Feeder Setup to see if the feeder is
configured to give you an alarm.
Calibration Weight Exceeded
Clean out the hopper and retest. If this doesn’t fix the problem,
then perform a scale calibration. Also, check to sure that the
Dump Time is not set extremely low. If all else fails, check the
value set for the Max Empty Weight. This might need to be
increased.
The feeder calibration values
are moving too much.
First, check that the displayed actual dispensed weight is accurate.
If this is OK, then check to see if the hopper is properly vented.
To do this, fill hopper and turn off the loader and retest.
BLN1-600A Chapter 6: Troubleshooting 84 of 116
Problem
Corrective action
I can’t calibrate the Scale
without an error message.
This Is caused by the difference in bits not being large enough.
Using the Direct Scale Readout, examine current loadcell bits with
and without the calibration weight. If the bits do not change
significantly, then check for pellets jamming the loadcells and
check the loadcell circuit. You might have a bad loadcell.
I can’t calibrate the feeder
without an error message.
Do other feeders calibrate correctly? Is the feeder I’m trying to
calibrate a large gate? If these are true, then lower the Batch % for
Feeder Cal setting under Feed Calibration Options. This can be
observed by looking at the Hopper Weight display.
None of the feeders calibrate? Check the Scale Calibration. If this
is correct, then lower the Batch% for Feeder Cal setting under Feed
Calibration Options for each feeder. This can be observed by
looking at the Hopper Weight display.
Weigh hopper does not empty
completely.
Check the dump time setting. It may be set too short.
If this does not correct the problem, clean the weigh hopper and
recheck the scale diagnostics readout. If not showing (0) zero when
empty, re-calibrate the scale.
Blender does not make rate.
Verify application is not exceeding blender capacity.
Verify additive percentage is not higher than designed, resulting in
excessive dispense time.
Verify all materials are feeding freely through the metering gates
or augers.
I have changed the recipe entry
mode, metering order, batch
size, inventory shutdown,
weigh every batch mode, or
feeder type and alarm flags, but
the change hasn’t taken place.
All of these settings are part of the current running recipe. This
makes it easy for the operator to load a stored recipe without
having to reconfigure all of these parameters for the new recipe.
All you have to do is touch “Accept New Recipe” to load these
values into the running recipe.
A feeder always puts too much
material in the batch.
Check that the Gate Cycle Time is set correctly. Try lowering this
value. If it is then lower the Initial % of Target to Meter. These
are found under Feed Algorithm Options. Make small adjustments
and retest.
A feeder is retrying more than
2-4 times.
Increase the Gate Cycle Time. This is found under Feed
Algorithm Options. Make small adjustments and retest.
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
Service Department.
BLN1-600A Chapter 7: Appendix 85 of 116
Chapter 7: 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: 40°C – Maximum (104°F)
3. Humidity range: 50% relative humidity
4. Altitude: Up to 1000m above sea level
5. Environment: Clean, dust-free and non-explosive
6. Radiation: 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%
10. Allowable frequency fluctuation: Continuous +/- 1%
Intermittent +/- 2%
11. The addition of an auger feeder (RAM option) for regrind will increase the electrical
supply requirements of a standard blender.
12. Nominal supply voltage: 120-240/1/60 or 110-220/1/50/60 (serial number tag)
13. Earth ground type: TN (system has one point directly earthed through a
protective conductor)
14. Power source should include a neutral power connection.
15. Over-current protection is supplied in the blender, but additional protection should be
supplied by the user. NFPA 70 article 430.24 to 430.26.
16. The plug on the power cord serves as the electrical disconnect device (located 0.6m
to 1.9m above floor).
17. Unit is not equipped with three-phase motors.
18. Blender is not equipped with local lighting.
19. Functional identification
20. Blender is equipped with an optional CE mark or UL label.
21. Blender is supplied with an operating manual in the language of the destination
country.
22. Cable support may be required for power cord, depending on final installation.
23. 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.
24. Doors can be opened with a screwdriver.
25. Two-hand control is not required or provided.
26. All blenders should be moved around and set in a place with a lift truck or equivalent.
27. There are no frequent repetitive cycles that require manual control!repetitive
functions are automatic while the blender is operating.
28. An inspection report detailing the functional test is included with the blender.
29. The machine is not equipped with cableless controls.
30. Color-coded (harmonized) power cord is sufficient for proper installation.
BLN1-600A Chapter 7: Appendix 86 of 116
7-1 Drawings and Diagrams
Final Assembly
Figure 55: Typical Final Assembly Parts List
#
Description
150
500
900
2500
4000
6000
1
Mixer Assembly
A0771710
A0771711
A0771715
A0771719
A0771723
A0771727
2
2-Component Hopper Assembly: DM/DM
N/A
892.03269.00
892.03020.00
892.04553.00
2-Component Hopper Assembly: DM/SQ
N/A
892.03270.00
892.04621.00
N/A
2-Component Hopper Assembly: SQ/SQ
N/A
A0771699
3-Component Hopper Assembly: DM/DM/DM
N/A
892.03271.00
892.03021.00
892.04554.00
3-Component Hopper Assembly: DM/DM/SQ
N/A
892.03272.00
892.04622.00
N/A
3-Component Hopper Assembly: SQ/DM/SQ
N/A
892.03275.00
Removable Hopper Small
892.02239.00
N/A
Removable Hopper Large
892.02411.00
N/A
3
Slide Gate Assembly – Major: DM/DM
N/A
A0771661
A0771660
A0771708
Slide Gate Assembly – Minor: DM/DM
N/A
A0771680
A0771661
A0771708
Slide Gate Assembly – Major: DM/SQ
N/A
A0771669
892.01510.00
A0771701
Slide Gate Assembly –Major: Single DM
N/A
A0569161
A0569160
A0771709
Slide Gate Assembly – Minor: Single DM
N/A
A0771681
A0569161
A0771709
Slide Gate Assembly – Major: Single SQ
N/A
A0771670
892.01513.00
A0771702
4
Valve Stack Assembly 4-Comp
N/A
A0771740
A0771868
Valve Stack Assembly 6-Comp
N/A
A0771741
A0771869
5
Main Controller
892.01809.00
892.1810.00
892.01811.00
6
Main Display (Not Shown)
892.00694.00
7
Main Display Cable 8 ft (Not Shown)
A0565856
8
Calibration Weight (Not Shown)
822.00334.00
822.00151.00
822.00152.00
A0571769
822.00153.00
9
Hopper Support Straps
N/A
A0569157
872.00246.00
10
Louvers – Hopper Covers
N/A
A0567625
DM: Diamond SQ: Square
BLN1-600A Chapter 7: Appendix 87 of 116
Mixer Sub-Assembly
BLN1-600A Chapter 7: Appendix 88 of 116
Figure 56: Typical Mixer Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
FRAME
872.00093.00
872.00094.00
A0770301
872.00224.00
2
FRAME EXTENSION (NOT SHOWN)
872.00208.00
N/A
872.00225.00
3
TOP PLATE
872.00095.00
872.00096.00
A0770300
872.00226.00
4
MOUNTING BRACKET – MIXER
MOTOR
872.00097.00
872.00098.00
A0770316
872.01318.00
5
MIX CHAMBER BACK PLATE
872.00099.00
872.00100.00
A0770333
872.00227.00
6
COUPLING – AGITATOR DRIVE
832.00010.00
832.0003.00
832.00181.00
7
AGITATOR – MIXING
872.00101.00
872.00102.00
872.01716.00
872.01470.00
8
DRAWER SUPPORT
832.00011.00
A0770320
832.00034.00
9
BUSHING – AGITATOR
832.00012.00
A0770319
832.00238.00
10
LOADCELL (TWO)
724.00767.00
724.00768.00
724.00770.00
724.00771.00
724.00771.00
11
MOUNTING BRACKET –
WEIGH HOPPPER
Right
872.01774.00
872.00519.00
Left
872.01280.00
12
COVER GUARD – LOADCELL
A0770322
872.00521.00
13
WEIGH HOPPER
A0771684
A0771685
A0771662
A0771704
A0771705
14
STOP RAIL – MIXER DRAWER
872.00105.00
872.00106.00
A0770314
872.00231.00
15
MIXER DRAWER
872.00107.00
872.00108.00
A0770315
872.00232.00
16
ACCESS DOOR – MIXER
832.00013.00
832.00014.00
A0770303
832.00035.00
832.00036.00
17
DOOR CLIPS
09990
18
SAFETY COVER – MIXER FRONT
(NOT SHOWN)
872.00109.00
N/A
19
DOOR LATCH
35454
20
SUPPORT BRACE – MIXER DOOR
N/A
872.00110.00
A0770332
872.00233.00
21
SAFETY COVER – MIXER BACK
872.00111.00
872.00112.00
A0770302
872.00234.00
22
MOUNTING BRACKET – CONTROL
PANEL (NOT SHOWN)
872.00124.00
N/A
23
PROXIMITY SENSOR – MIXER
HIGH-LEVEL
A0556548
24
SYSTEM-STOP SAFETY
DISCONNECT SWITCH
721.01058.02
25
SAFETY DISCONNECT SWITCH –
MIXER DOOR
717.00078.00
26
GEAR MOTOR
Motor
720.00001.00
720.00002.00
51354
Reducer
N/A
160.00280.00
Right angle reducer
51415
27
FLOW VALVE 1/4" TUBING
A0770190
BLN1-600A Chapter 7: Appendix 89 of 116
Hopper Sub-assembly
Figure 57: Typical Hopper Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
2-COMPONENT HOPPER
Consult Factory
3-COMPONENT HOPPER
2
LEXAN DOOR
A0770286
3
DOOR LATCH
A0770076
4
3.5” SIGHT GLASS
832.00096.00
N/A
5
4.5” SIGHT GLASS
N/A
832.00095.00
6
(OPTIONAL) 2” DRAIN W/ MANUAL GATE
(NOT SHOWN)
A05771782
N/A
(OPTIONAL) 3” DRAIN W/ MANUAL GATE
(NOT SHOWN)
N/A
A0771783
7
(OPTIONAL) BRACKET - LOW-LEVEL
SENSOR (NOT SHOWN)
A0569155
8
(OPTIONAL) PROXIMITY SENSOR LOW-
LEVEL (NOT SHOWN)
A0556548
730.00024.00
BLN1-600A Chapter 7: Appendix 90 of 116
Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional)
Figure 58: Typical R.A.M. Hopper Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
THROAT
N/A
07822-1
2
CLAMP
A0548808
3
FEEDER TUBE
872.00506.00
872.00426.00
872.00699.00
4
DRAIN HOUSING
08806A-HYD
5
DRAIN SLIDE GATE
08806B
6
MOTOR MOUNT BRACKET
08451
7
SEAL – AUGER - TEFLON
55372
8
MOTOR - AUGER
720.00004.00
720.00028.00
9
AUGER
872.00507.00
872.00421.00
872.00698.00
10
HOPPER 2.0 CU.FT.
872.00417.00
N/A
HOPPER 7.0 CU.FT.
N/A
872.00418.00
11
DOOR
A0770286
12
LATCH
A0770076
13
SAFETY INTERLOCK SWITCH
717.00078.00
14
BRACKET – SAFETY SWITCH
872.00431.00
15
SIGHTGLASS 4.5”
832.00095.00
16
MOTOR – AGITATOR
51489
17
AGITATOR
10637
18
SEAL – AGITATOR - RUBBER
15286
19
RECEPTACLE – 3-PIN FEMALE
63119
20
CORD 3-PIN MALE 6 FT LONG
55196
21
STEADY STATE RELAY – 10 AMP
729.00183.00
22
GLASS FUSE – 3.0 AMP (115V UNIT)
A0542207
GLASS FUSE – 1.5 AMP (230V UNIT)
725.00885.00
BLN1-600A Chapter 7: Appendix 91 of 116
Hopper Additive Feeder Sub-Assembly (Optional)
Figure 59: Typical Additive Feeder Hopper Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
THROAT
N/A
A0541201
2
MOTOR MOUNT BRACKET
A0541229
3
MOTOR – AUGER
51450G
4
THROAT ADAPTER – 2” RISER
872.00537.00
5
HOPPER 1.0 CU.FT.
A0541207
N/A
HOPPER 2.0 CU.FT.
N/A
A0541208
6
SIGHTGLASS – AF
A0541206
7
COVER PLATE – HOPPER
CLEANOUT
A0541215
8
COVER PLATE – SAMPLE PORT
A0541216
9
TRANSFER TUBE – 1” AUGER
A0541211
10
AUGER ASSEMBLY – 1” AUGER
A0541294
11
COUPLING – MOTOR/AUGER
A0541282
12
PIN – MOTOR MOUNT (NOT SHOWN)
A0541277
13
RECEPTACLE – 3-PIN FEMALE
(NOT SHOWN)
63119
14
CORD 3-PIN MALE 6 FT LONG
(NOT SHOWN)
55196
15
STEADY STATE RELAY – 10 AMP
(NOT SHOWN)
729.00183.00
16
GLASS FUSE – 3.0 AMP (115V UNIT)
(NOT SHOWN)
A0542207
GLASS FUSE – 1.5 AMP (230V UNIT)
(NOT SHOWN)
723.00885.00
BLN1-600A Chapter 7: Appendix 92 of 116
Weigh Hopper Sub-assembly
Figure 60: Typical Weigh Hopper Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
WEIGH HOPPER
872.00103.00
872.00104.00
A0770312
872.00229.00
872.00230.00
2
AIR CYLINDER
245.00003.00
A0770248
3
CLEVIS – AIR
CYLINDER
35460
35449
4
FITTING – AIR
TUBING
A0770126
35085K
5
AIR TUBING
(NOT SHOWN)
A0770139
207.00021.00
BLN1-600A Chapter 7: Appendix 93 of 116
Slide Gate Sub-assembly
Figure 61: Typical Slidegate Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
HOUSING (DOUBLE DIAMOND) (#1-4)
Consult Factory
HOUSING (SQUARE / DIAMOND) (#1-4)
HOUSING (DOUBLE DIAMOND) (#5-6)
2
GATE – DIAMOND (#1-4)
A0770309
A0770305
872.00237.00
GATE – SQUARE (#1-4) (NOT SHOWN)
872.00116.00
872.00763.00
872.00236.00
GATE – DIAMOND (#5-6)
872.00115.00
A0770309
872.00237.00
3
GUIDE ROD (#1-4)
A0770311
A0770307
832.00037.00
GUIDE ROD (#5-6)
832.00015.00
A0770311
4
AIR CYLINDER (#1-4)
35448
35448
245.00016.00
AIR CYLINDER (#5-6)
245.00006.00
5
CLEVIS – AIR CYLINDER (#1-4)
35449
35449
A0770296
CLEVIS – AIR CYLINDER (#5-6)
35460
6
FITTINGS – AIR CYLINDER
A0770136
35086K
7
STROKE LIMITER (#1-4)
822.00966.00
A0770306
822.00997.00
STROKE LIMITER (#5-6)
822.00946.00
A0770310
BLN1-600A Chapter 7: Appendix 94 of 116
Knife Gate Sub-assembly HD (Optional)
Figure 62: Typical Slide Gate (below mixer) Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
1
BASE FRAME
07990
2
MOLDED THROAT
53413
3
SPACER PLATE
08286
4
FLANGE ADAPTER
08292
5
KNIFE BLADE
10644
6
MOUNTING BRACKET – AIR CYLINDER
33088
7
AIR CYLINDER
33091
8
-
-
9
MOUNTING NUT – AIR CYLINDER
A0553239
10
CLEVIS – AIR CYLINDER
33090
11
BUSHING 1/4 - 1/8 NPT
35014
12
ELBOW 1/8 NPT
35118
13
SOLENOID 4-WAY 24VDC
33128
14
FITTING – 1/8 NPT X 1/4 TUBE
35086K
15
MUFFLER 1/8 NPT FLUSH
35157
16
FITTING – 1/4 NPT X 1/4 TUBE
35154
17
SAFETY SHIELD
A0770362
A0770363
A0770364
A0770365
18
STROKE LIMITER PIPE (NOT SHOWN)
07990B
BLN1-600A Chapter 7: Appendix 95 of 116
Knife Gate Sub-assembly RD (Optional)
Figure 63: Typical Slide Gate (floor stand) Assembly Parts List
#
DESCRIPTION
All Models
1
HOUSING FRAME
872.00297.00
2
GUARD SAFETY COVER
872.00298.00
3
ROD GUIDE
832.00049.00
4
GATE – SLIDE BLADE
872.00236.00
5
AIR CYLINDER
245.00016.00
6
CLEVIS – AIR CYLINDER
A0770296
7
NUT – LOCKING
A0533862
8
FITTING ELBOW 1/8 NPT X 1/4 TUBE
35086K
9
NIPPLE 1/8 NPT
025.01020.00
10
SOLENOID 4-WAY 24VDC
33128
11
FITTING STRAIGHT 1/8 NPT X 1/4 TUBE
35085K
12
FITTING MUFFLER STONE 1/8 NPT
35157
BLN1-600A Chapter 7: Appendix 96 of 116
Control Panel Layout
Figure 64: Typical Allen-Bradley Controller Main Parts List*
#
Description
150
500
900
2500
4000
6000
1
Allen-Bradley PLC MicroLogix 1500
891.00024.00
2
Allen-Bradley PLC Base Unit
891.00744.00
3
24 vdc Power Supply
A0563932
4
Calex Module – Load Cell Amplifier
724.00117.00
5
Alarm Light Red Beacon 24 vdc
736.00063.00
6
Alarm Horn 95db 24vdc
736.00059.00
7
Motor Contactor
729.00202.02
8
Motor Overload – MCP (115v unit)
A0558252
A0558255
A0558256
Motor Overload – MCP (230v unit)
A0558251
A0568738
A0558255
9
Power Switch (115v unit)
717.01040.02
Power Switch (230v unit)
10
Safety Active 24vdc
Figure 65: Typical RED LION Display Main Parts List
#
Description
150
500
900
2500
4000
6000
1
Red Lion G306A
Touchscreen Display
6” Main
744.00325.00
6” Remote
744.00325.00
2
Enclosure Mounting Feet
A0567132
3
Display – 8 ft Connection Cable
A0565856
Display – 50 ft Connection Cable
A0565899
* Parts list for current blender software (Rev 4.X or higher). Consult factory for Pre 4.X software blender.
BLN1-600A Chapter 7: Appendix 97 of 116
PORTANT INFORMATION CONCERNING MAX. BLENDING RATE LISTED:
• The standard maximum blending rate is based on a 3-component blend running 80% virgin, 18% regrind (free-flowing)
and 2% pelletized color. Each additional component reduces the overall maximum rate by 20% per component.
• Recipes with more than 50% regrind will significantly reduce the throughput, and minor ingredient accuracy, of the
blender. Consult the factory for achievable rates.
• Two component recipes may REDUCE overall blender throughput due to reduced available weigh hopper capacity.
Consult the factory for achievable rates.
• Rates are based on dry, free-flowing virgin pellets with a bulk density of 35 lbs./ft3. Rates will vary as a result of the
number of blender components, the materials, and the recipe(s) used. Consult the factory for guaranteed rates.
• Material samples are required for testing prior to shipment for guaranteed rates. Consult the AEC Sales Department for
shipping instructions and for the amounts of each material to send for testing. A test request form must be submitted,
Component Watt Rating
120/24 VDC
Supply
AB/Mitsubishi
PLC
IEC Contactors
Relays
Solenoids
Lamps
.6A 24W
Allen Bradley
88
CO9-30
8/70VA
C37
9/80VA
4PDT
1.2VA
¼"
16/30VA
Full Volt 3W
C43
10/130VA
C60-85
16/200VA
2.1A 50W
Mitsubishi
50W
D110
37/370VA
D180
37/370VA
2DPT
1.2VA
½"
16/30VA
Transformer
1.5W
D250, D300
37/370VA
D400 37/370VA
D600
37/370VA
Machine Tool
19/138VA
¾", 1"
6.1W
IDI INCAND
.5W
Mixer Motor Amp Rating
Part Number
HP
FLA @ 230VAC
FLA @ 115VAC
Starting Current
@ 230VAC
Starting Current
@ 115VAC
720.00001.00
1/6
1.0 AMP
2.1 AMP
2.5 AMP
5 AMP
720.00002.00
1/3
3.3 AMP
6.6 AMP
18 AMP
36 AMP
720.00030.00
1/2
N/A
7.8 AMP
24 AMP
48 AMP
51354
1
7.0 AMP
14.0 AMP
21 AMP
41 AMP
BLN1-600A Chapter 7: Appendix 98 of 116
7-3 Spare Parts Kits *
Figure 66: Blender Spare Parts Listing
Spare Parts Kits
BD; CSG; SGBD
150
500
900
2500
4000
6000
“A” Kit - Consumables
A0574120
A0574134
A0574137
A0574125
A0574140
A0574143
Load cell assembly
#
724.00767.00
724.00768.00
724.00770.00
724.00771.00
724.00772.00
Mixer high-level sensor
#
A0556548
“B” Kit - Minimal Downtime
A0574121
A0574135
A0574138
A0574126
A0574141
A0574144
All “A” kit parts
A0574120
A0574134
A0574137
A0574125
A0574140
A0574143
Slide Gate Air Cylinder -Majors
#
35448
245.00016.00
Slide Gate Air Cylinder -Minors
#
245.00006.00
35448
245.00016.00
Weigh Hopper Air cylinder
#
245.00003.00
A0770248
Contactor - mixer motor
729.00202.02
Power supply – 24 vdc
A0563932
Mixer Door Safety Switch
#
717.00078.00
Circuit Breaker (2 amp) x 2
727.00207.00
Circuit Breaker (3 amp) x 2
727.00208.00
“C” Kit (24/7 Operation or International)
A0574122
A0574136
A0574139
A0574127
A0574142
A0574145
All “A” and “B” Kit Parts
A0574121
A0574135
A0574138
A0574126
A0574141
A0574144
Second Load Cell Assembly w/o plug
#
724.00767.00
724.00768.00
724.00770.00
724.00771.00
724.00772.00
Mixer Motor Protector (overload)
A0558252
A0558255
Calex Module
724.00117.00
Other Recommended Parts
150
500
900
2500
4000
6000
Mixer gear motor
CTH002553
720.00001.00
720.00002.00
720.51354.00
Reducer
N/A
160.00280.00
Right Angle Reducer
51415
Mixer agitator
#
872.00101.00
872.00102.00
872.01716.00
872.01470.00
Mixer coupling
#
832.00010.00
832.00030.00
Weigh hopper assembly
#
A0771684
A0771685
A0771662
A0771704
A0771705
4-component SMC valve stack assembly
CF
A0771740
A0771868
6-component SMC valve stack assembly
N/A
A0771741
A0771869
A-B PLC Micrologix CPU
891.00024.00
Allen-Bradley PLC flash memory card
891.00008.00
Red Lion Touch Screen
744.00325.00
* Parts list for current blender software (Rev 6.1 or higher). Consult factory for Pre 6.1 software blender.
BLN1-600A Chapter 7: Appendix 99 of 116
7-4 Addendum (Service Supervisor Information)
After all selections are made: Keep pressing the button until the unit
returns to the Recipe menu.
Passwords
• User Password “5413”
• Maintenance Password “3145348”
Maintenance password should only be supplied to qualified personnel! The
program can be compromised.
• This section of the manual should not be used by untrained personnel –
blender controller and/or program can be compromised!
• Hidden, programmable features and hidden menu pages should not be made
available to floor operators. These pages 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.
• Programmable features should not be accessed by inexperienced operators
or inexperienced plant personnel. Unauthorized changes may prevent the
blender from operating properly and may void part or all of the warranty.
• 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.
• Information included in this manual is subject to change without notice.
BLN1-600A Chapter 7: Appendix 100 of 116
Programmable Settings
The Batch 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.
This menu is accessed by pressing the manufacturer’s icon when in the “Setup” Directory
Screen menu.
Enter the long password “3145348” and press “Enter”.
Advanced Setup Menu
Metering Test Screen
This screen is useful when testing the metering performance of each feeder. The user can
perform test to evaluate the mechanical standard deviation of the gate or auger. This test
meters for the calculated time based off the target weight entered on this screen. The blender
does not retry or adjust the time of the meter to reach the target. This allows you to open the
gate for several feeds using the same time. You can then record the Dispensed Grams and
plot the standard deviation of the gate. The other purpose of this screen is to verify that the
dispensed weight displayed is correct. You can perform a meter and then pull the weigh
hopper to weigh the material on a gram scale. Refer to the Troubleshooting Section of this
manual for additional details.
Touch here and enter
in the Supervisor or
Maintenance
Password to access
the Advanced Setup
Menu
Enable/Disable
Security
BLN1-600A Chapter 7: Appendix 101 of 116
Advanced Weight Options Screen and Feeder Calibration Setup
WEIGHT FILTER: The number of loadcell samples to be averaged when determining
weight.
MAX TARE OFFSET: Maximum allowed weight remaining in weigh hopper after dumping
before “Calibration Error Alarm”.
WEIGHT/SEC FILTER: This is only used if the “Weight Per Second Buffer” is off. This is
a weighted median filter that will dampen changes to the Weight /Sec value of each feeder.
Increasing this will dampen the change.
WEIGHT PER SECOND BUFFER: When enabled the blender analyzes 3 consecutive
batches “Weight/Sec” measured values. If these 3 are within the “Allowed Deviation for
Stable Flag” (“Feeder Calibration Setup Page”) then the measurements are considered stable.
If the blender has went through a certain number of batches without stabilizing (“Unstable
Alarm Limit” on “Feeder Calibration Setup Page”) then an “Unstable Alarm” will occur for
that feeder. The 3 measurements are averaged to come up with the “Wt/Sec” value (“Feeder
Calibration Page”). This is then used when calculating the metering time for that ingredient.
When this feature is disabled then every feed calculates a new Wt/Sec value that is then
weighted using the Weight/Sec Filter in order to smooth out changes.
% ABOVE BATCH SIZE FOR MAX WEIGHT ALARM: This is the trigger point above the
batch size that will initiate a “Hopper Over Max Alarm”. This is designed to prevent the
weigh hopper from being overfilled volume wise. Care should be taken when adjusting the
batch size of this parameter to make sure that they are appropriate.
BATCH DUMP SETTLE TIME: Amount of time to weight after batch door is closed before
taking weight snapshot.
LOADCELL SAMPLE TIME: The sample time for each weight snapshot. It is important
that the mechanical settle time for each feeder be longer than WEIGHT FILTER *
LOADCELL SAMPLE TIME. For instance if the defaults are used then you end up with 5 *
.5 seconds = 2.5 seconds. Therefore 3 seconds is the absolute shortest settle time you can
have for each feeder (under MECHANICAL OPTIONS).
SIMULATION: Simulation is only used for Demo purposes and should not be turned on for
normal blender operation. When enabled this allows a user to practice using the controller as
if it were attached to an actual blender. A PLC is required for this simulation.
PRINT WEIGHT DATA EVERY BATCH: The blender’s touch screen has a serial printer
port that you can connect a serial ASCII printer to. The data that is dumped to a printer is the
same data shown on the Recipe Screen. No averaging is done with the data shown to the
Customer. Targets vs. Actual are actually what is in the batch.
BLN1-600A Chapter 7: Appendix 102 of 116
Feed Algorithm Options Screen
INITIAL TARGET PERCENT: This is the % of target that the feeder will use to calculate
the initial meter time of each batch for that feeder. After the feeder has metered initially for a
particular batch then this value is not used.
UNDER LIMIT: Allowed underfeed of target weight for that feeder. After the meter has
completed the weight is observed. If the weight is within the target by this amount then that
feeder has completed metering and the blender moves to the next ingredient. If it is not
satisfied than the blender will repeat metering until this amount is reached. The blender will
retry forever or until the operator hits on the recipe page.
OVER LIMIT: If after metering it is determined that a feeder has metered a value greater
than the target + Over Limit weight then a counter is incremented. If this counter reaches the
OVERFEED COUNT LIMIT (Advanced Alarm Options Page) then a “OVERFEED
ALARM” will occur.
DOUBLE GATE THRESHOLD: After a feeder has retried for this many retries then the
GATE CYCLE TIME is temporarily doubled until the target is reached. This is used as a
preventative measure in the case the user has set the GATE CYCLE TIME too low for that
feeder (Mechanical Options Page).
BATCHES FOR PROCESS RATE: The process rate on the Inventory Screen is the rate at
which the customer is using the blend. Since a batch blender does not have a loss in weight
hopper to measure this take-away rate then the process rate is only an estimate. This value
helps to improve that value. This is the number of batches required before calculating the
process rate. The blender must hit high level at least twice and have made this number of
batches before a rate will be calculated. The error is always +/- 1 batch. If you set this value
to “10” then that means the process rate error will be +/- 10%. If you want to improve the
error increase this value, but this will delay getting a process rate number. If set to 100 then
the error would be +/- 1%.
STANDARD VS ADVANCED ALGORITHM: The blender should be set to Standard for
most cases. However, if enabled you can meter in the first ingredient and then all other
ingredients will be recalculated based on the actual meter of the first ingredient. To do this
you will need to lower the batch size by the % you expect the first ingredient to be in error.
You must also increase the % ABOVE BATCH SIZE FOR MAX WEIGHT ALARM by the
same amount. Doing this will lower your overall throughput capability of the blender, but
will increase accuracy by about a factor of 10.
BLN1-600A Chapter 7: Appendix 103 of 116
Mechanical Options Screen
GATE CYCLE TIME: The gate cycle time has been measured and set at the factory, but
might need to be adjusted if we change the mechanical design of the gate, solenoids, or air
cylinders. This setting will vary depending on whether you are using a gate or an auger.
Essentially it is the amount of time required to open/close or start/stop the feeding device.
SETTLE TIME: The amount of time to settle the weigh hopper after the feeder has metered
before determining final weight. Be sure that this is set to a value greater than WEIGHT
FILTER * LOADCELL SAMPLETIME (both on “Advanced Weight Options Page”). Never
set less than 3 seconds.
NUMBER OF LOADCELLS: based on your blender’s configuration.
MIXER BUMP TIME: if the mixer is at high level it will bump the mixer on for this many
seconds every 30 seconds. This helps prevent an issue where the high level prox is set
incorrectly and picking up the mixer blade instead of actually being at high level.
MIX SINGLE BATCHES: Mixes single batches and then dumps them into the process. If
set to “MIX TO FULL” then it will mix multiple batches together before dumping them into
the process. This is useful when filling gaylords in order to achieve batch to batch averaging.
BLN1-600A Chapter 7: Appendix 104 of 116
Feeder and Type Setup
This page allows you to configure how many hoppers your unit has as well as the position of
each feeder visually. You can make any hopper any number as long as you don’t skip a
number. For instance if you have a 4 component blender then you will need to make sure you
have the numbers 1-4 configured into a hopper. Never assign the same number to multiple
feeders. Set unused hoppers to “0” will hide them on the recipe page. You should configure
the blender to match the actual physical location of each hopper to make it easier on the
operator. However, this is only a visual issue and does not effect operation of the blender.
This screen also allows you to modify the type of each feeder. In most cases, the user will
want to keep regrind on hopper 3 because that blender has been specifically designed to
handle the regrind. These settings should only be modified under special circumstances.
If the blender is configured in “EZ Mode” then one hopper must be configured for Regrind
and at least one hopper must be configured for Virgin material. If this is incorrect, a message
will be given on the Recipe Screen. You can configure as many Regrind or Virgin hoppers as
you want. Hopper Material Type tags are only used in EZ MODE.
BLN1-600A Chapter 7: Appendix 105 of 116
Advanced Alarm Options
OUT OF MATERIAL RETRY LIMIT FOR ALARM: the number of retries before an out of
material alarm is given. The blender also uses the gain in weight to determine this, but in the
case where the weight change wasn’t enough this is used to catch the Out of Material
condition. Low Level prox switches can also be used to give the earliest indication.
SURGE EMPTY DELAY: the number of seconds before triggering a Surge Hopper Empty
Alarm. This is an optional feature and doesn’t necessarily represent the blender’s surge
hopper. Typically this can be used to indicate the take off box below the blender is empty.
UNABLE TO MAKE RATE DELAY: if the high level prox hasn’t been covered after this
amount of time then an alarm is given indicating that the blender cannot keep up.
OVERFEED BATCH DELAY: the number of batches allowed upon starting the blender
before examining for an overfeed condition.
OVERFEED COUNT LIMIT: the number of overfeeds that must occur before an alarm.
RUN/STOP ON ALARM BUTTONS: determines if the blender should continue running or
should stop when these alarms occur. If the blender is stopped due to an alarm condition then
the alarm will stay active until the operator silences it.
IO Options
This page is used to configure optional alarm inputs. The options are HOP6 low level or
Mixer instant close feature (used with metal separator). HOP7 low level or Surge Hopper
Empty Feature (used to detect a low level anywhere). HOP8 low level or Mixer Failure Prox
(used to detect a mixer that has stopped turning).
BLN1-600A Chapter 7: Appendix 106 of 116
Password Setup
Use this page to configure all passwords.
Diagnostic Data
This page is used to monitor target vs. actual data for all feeders.
BLN1-600A Chapter 7: Appendix 107 of 116
Factory Default Parameters
BLN1-600A Chapter 7: Appendix 108 of 116
BLN1-600A Chapter 7: Appendix 109 of 116
7-5 COMMUNICATIONS AND WEB SERVER
The Blender has a Red Lion touch screen that has a built in Ethernet port. This port’s IP address can
be configured via SETUP/DISPLAY CONFIG. Once configured you can connect the display to your
plant’s network. The display software has a built in webserver that will allow you to view and control
your blender as if you were in front of it using any web enabled device or computer. If your facility
has WiFi then the blender can be viewed controlled wirelessly via your smartphone.
Open your web browser and in the address bar enter the IP address for the blender’s display. This
will bring up a page where you can either view the blender’s data logs or use the remote view feature.
AB COMMUNICATIONS INFORMATION
The AB blender uses a Micrologix 1500 LRP processor that communicates with the outside world
using DF1 protocol with Ethernet hardware. Its Ethernet speed is 10/100 Mbits/second. The blender
must be purchased from ACS with the Ethernet option. If this was not done at the time of purchase it
can be added afterwards by consulting the factory. The blender has a programmable IP address and
subnet mask that can be programmed from the Panel View that comes with the blender (refer to
blender manual).
Ethernet is the standard that we support, but AB also supports Device Net, DF, and DH485 protocol
to these PLCs. Refer to AB documentation.
The DF1 port is 19200 baud with no parity and a source ID of 1. This is usually not important since
you will be communicating with the Ethernet module instead of directly with the DF1 port. Be sure
that the DCOMM light is on by depressing the COMMS switch under the PLC front panel. After this
light is on then you can touch the ACS icon and enter “5413”, then select Ethernet Setup, program in
you IP address, click “send config to module”, and then wait about 45 seconds for it to program the
new IP address. If you cannot ping the module then reboot the blender and try again 45 seconds after
booting.
Below are the items that can be accessed for the blender:
GENERAL BLENDER INFO
1 (R) plc_version,n23:0 (xx.x)
2 (R) number_of_hoppers,n9:9 (number of hoppers on the blender)
3 (R) maximum_blender_throughput,L15:24,f39:1 (maximum rate blender can achieve)
• ITEMS MARKED (R) ARE READ ONLY AND ITEMS MARKED (RW)
ARE READ/WRITE
BLN1-600A Chapter 7: Appendix 110 of 116
4 (R) average_batch_time, n16:3 (average amount of time it takes to finish the batch)
5 (R) average_process_rate,L30:30,f39:2 (average rate at which the process is consuming blended
material)
BLENDER STARTING AND STOPPING
1 (R) blender_started,b3:0/0
2 (RW) blender_start_request,b3:0/11 (toggle this to start or stop the blender, blender will switch it’s
current status, you must also reset this bit after completion)
3 (RW) abort_batch_request,b3:0/8 (toggle this to immediately stop the blender even if the batch is
incomplete, you must also reset this bit after completion)
BLENDER ALARMS
1 (R) alarm_number,n11:74 (see below for description)
2 (R) hop1_out_of_material,b28:0/0
3 (R) hop2_out_of_material,b28:0/1
4 (R) hop3_out_of_material,b28:0/2
5 (R) hop4_out_of_material,b28:0/3
6 (R) hop5_out_of_material,b28:0/4
7 (R) hop6_out_of_material,b28:0/5
8 (R) hop7_out_of_material,b28:0/6
9 (R) hop8_out_of_material,b28:0/7
10 (R) hopper_over_max_alarm,b28:0/9
11 (R) empty_weight_exceeded,b28:0/10
12 (R) inventory_cleared,b28:0/11 (use this bit to record when an operator cleared the inventory at the blender)
13 (R) power_interruption,b28:0/15 (this alarm engages when the PLC loses power during a batch)
14 (R) hop1_low_level,b29:2/0 (this alarm is only available if the hoppers have low level prox switches)
15 (R) hop2_low_level,b29:2/1 (this alarm is only available if the hoppers have low level prox switches)
16 (R) hop3_low_level,b29:2/2 (this alarm is only available if the hoppers have low level prox switches)
17 (R) hop4_low_level,b29:2/3 (this alarm is only available if the hoppers have low level prox switches)
18 (R) hop5_low_level,b29:2/4 (this alarm is only available if the hoppers have low level prox switches)
19 (R) hop6_low_level,b29:2/5 (this alarm is only available if the hoppers have low level prox switches)
20 (R) hop7_low_level,b29:2/6 (this alarm is only available if the hoppers have low level prox switches)
21 (R) hop8_low_level,b29:2/7 (this alarm is only available if the hoppers have low level prox switches)
22 (R) plc_battery_low,s:5/11
23 (R) plc_memory_module_loaded,s:5/8 (this alarm only happens while upgrading the blender’s software)
BLN1-600A Chapter 7: Appendix 111 of 116
INVENTORY INFO
1 (RW) clear_inventory,b3:0/3 (toggle this to clear all inventory, you must also reset this bit after
completion)
2 (RW) batch_counter,L30:31,f39:37 (number of batches made)
3 (R) hop1_inventory,L30:0 (this is the whole portion of the inventory) , f39:3 (entire number)
4 (R) hop2_inventory,L30:1 (this is the whole portion of the inventory) , f39:4 (entire number)
5 (R) hop3_inventory,L30:2 (this is the whole portion of the inventory) , f39:5 (entire number)
6 (R) hop4_inventory,L30:3 (this is the whole portion of the inventory) , f39:6 (entire number)
7 (R) hop5_inventory,L30:4 (this is the whole portion of the inventory) , f39:7 (entire number)
8 (R) hop6_inventory,L30:5 (this is the whole portion of the inventory) , f39:8 (entire number)
9 (R) hop7_inventory,L30:6 (this is the whole portion of the inventory) , f39:9 (entire number)
10 (R) hop8_inventory,L30:7 (this is the whole portion of the inventory) , f39:10 (entire number)
11 (R) batch_inventory,L30:35 (this is the whole portion of the inventory) , f39:11 (entire number)
12(R) hop1_fractional_inventory,L30:16 (this is the fractional part of the inventory .xxx)
13 (R) hop2_fractional_inventory,L30:17 (this is the fractional part of the inventory .xxx)
14 (R) hop3_fractional_inventory,L30:18 (this is the fractional part of the inventory .xxx)
15 (R) hop4_fractional_inventory,L30:19 (this is the fractional part of the inventory .xxx)
16 (R) hop5_fractional_inventory,L30:20 (this is the fractional part of the inventory .xxx)
17 (R) hop6_fractional_inventory,L30:21 (this is the fractional part of the inventory .xxx)
18 (R) hop7_fractional_inventory,L30:22 (this is the fractional part of the inventory .xxx)
19 (R) hop8_fractional_inventory,L30:23 (this is the fractional part of the inventory .xxx)
20 (R) batch_inventory_decimal_part,L30:39 (this is the fractional part of the inventory .xxx)
BLN1-600A Chapter 7: Appendix 112 of 116
RECIPE INFO (THIS IS WHERE YOU RIGHT THE NEW RECIPE TO)
1 (RW) temp_recipe_entry_mode,n9:11 (0=percentage mode, 1=parts mode, 2=EZ mode)
2 (R) temp_batch_size_recipe_value,L21:53 (xxx.x lbs or kgs)
3 (RW) pv1_hop1_temp_recipe_value,L20:0 (xxx.xx, write your new recipe here)
4 (RW) pv1_hop2_temp_recipe_value,L20:1 (xxx.xx, write your new recipe here)
5 (RW) pv1_hop3_temp_recipe_value,L20:2 (xxx.xx, write your new recipe here)
6 (RW) pv1_hop4_temp_recipe_value,L20:3 (xxx.xx, write your new recipe here)
7 (RW) pv1_hop5_temp_recipe_value,L20:4 (xxx.xx, write your new recipe here)
8 (RW) pv1_hop6_temp_recipe_value,L20:5 (xxx.xx, write your new recipe here)
9 (RW) pv1_hop7_temp_recipe_value,L20:6 (xxx.xx, write your new recipe here)
10 (RW) pv1_hop8_temp_recipe_value,L20:7 (xxx.xx, write your new recipe here)
11 (R) pv1_recipe_error_message,n9:2 (1=total not 100%, 2=feeder type error, 3=entry over 100%)
12 (R) pv1_accept_recipe_enabled,b3:0/4 (this bit goes high if a new recipe is valid)
13 (RW) pv1_accept_recipe_requested,b3:0/6 (toggle this bit to accept a valid recipe, you must also
reset this bit after completion)
CURRENT RECIPE INFO (THIS IS THE RECIPE THAT IS CURRENTLY BEING MADE)
1 (R) current_recipe_entry_mode,n9:1 (0=percentage mode, 1=parts mode, 2=EZ mode)
2 (R) current_batch_size_recipe_value,L21:20 (xxx.x lbs or kgs), f39:36
3 (R) current_hop1_recipe_value,L21:11 (xxx.xx, recipe value for running recipe), f39:12
4 (R) current_hop2_recipe_value,L21:12 (xxx.xx, recipe value for running recipe) , f39:13
5 (R) current_hop3_recipe_value,L21:13 (xxx.xx, recipe value for running recipe) , f39:14
6 (R) current_hop4_recipe_value,L21:14 (xxx.xx, recipe value for running recipe) , f39:15
7 (R) current_hop5_recipe_value,L21:15 (xxx.xx, recipe value for running recipe) , f39:16
8 (R) current_hop6_recipe_value,L21:16 (xxx.xx, recipe value for running recipe) , f39:17
9 (R) current_hop7_recipe_value,L21:17 (xxx.xx, recipe value for running recipe) , f39:18
10 (R) current_hop8_recipe_value,L21:18 (xxx.xx, recipe value for running recipe) , f39:19
HIDDEN RECIPE INFO (THIS IS THE RAW RECIPE THAT WILL BE LOADED AT NEXT
BATCH)
1 (R) recipe_entry_mode,n9:0 (0=percentage mode, 1=parts mode, 2=EZ mode)
2 (R) batch_size_recipe_value,L21:9 (xxx.x lbs or kgs)
3 (R) hop1_recipe_value,L21:0 (xxx.xx, recipe value for running recipe)
4 (R) hop2_recipe_value,L21:1 (xxx.xx, recipe value for running recipe)
5 (R) hop3_recipe_value,L21:2 (xxx.xx, recipe value for running recipe)
6 (R) hop4_recipe_value,L21:3 (xxx.xx, recipe value for running recipe)
7 (R) hop5_recipe_value,L21:4 (xxx.xx, recipe value for running recipe)
8 (R) hop6_recipe_value,L21:5 (xxx.xx, recipe value for running recipe)
9 (R) hop7_recipe_value,L21:6 (xxx.xx, recipe value for running recipe)
BLN1-600A Chapter 7: Appendix 113 of 116
10 (R) hop8_recipe_value,L21:7 (xxx.xx, recipe value for running recipe)
11 (R) recipe_target_total,L21:8 (xxx.xx, the is the total of hop1-hop8 from above, you must manually
add this if you chose to skip the blenders error checking, you must also ensure that you are in the
correct recipe_entry_mode! SEE BELOW FOR DETAILS)
TARGETS VS. ACTUAL WEIGHT INFO
1 (R) print_data_now,b3:1/11 (read this tag and when it goes high record the actual weights)
2 (R) hop1_displayed_target_weight,L18:0 (target meter weight for batch, xxx.xxx) , f39:20
3 (R) hop2_displayed_target_weight,L18:1 (target meter weight for batch, xxx.xxx) , f39:21
4 (R) hop3_displayed_target_weight,L18:2 (target meter weight for batch, xxx.xxx) , f39:22
5 (R) hop4_displayed_target_weight,L18:3 (target meter weight for batch, xxx.xxx) , f39:23
6 (R) hop5_displayed_target_weight,L18:4 (target meter weight for batch, xxx.xxx) , f39:24
7 (R) hop6_displayed_target_weight,L18:5 (target meter weight for batch, xxx.xxx) , f39:25
8 (R) hop7_displayed_target_weight,L18:6 (target meter weight for batch, xxx.xxx) , f39:26
9 (R) hop8_displayed_target_weight,L18:7 (target meter weight for batch, xxx.xxx) , f39:27
10 (R) hop1_displayed_actual_weight,L19:0 (actual metered weight in batch, xxx.xxx) , f39:28
11 (R) hop2_displayed_actual_weight,L19:1 (actual metered weight in batch, xxx.xxx) , f39:29
12 (R) hop3_displayed_actual_weight,L19:2 (actual metered weight in batch, xxx.xxx) , f39:30
13 (R) hop4_displayed_actual_weight,L19:3 (actual metered weight in batch, xxx.xxx) , f39:31
14 (R) hop5_displayed_actual_weight,L19:4 (actual metered weight in batch, xxx.xxx) , f39:32
15 (R) hop6_displayed_actual_weight,L19:5 (actual metered weight in batch, xxx.xxx) , f39:33
16 (R) hop7_displayed_actual_weight,L19:6 (actual metered weight in batch, xxx.xxx) , f39:34
17 (R) hop8_displayed_actual_weight,L19:7 (actual metered weight in batch, xxx.xxx) , f39:35
CUSTOMER FREE STORAGE SPOTS (use for anything)
1 (RW) customer_free_spot, f42:0
2 (RW) customer_free_spot, f42:1
BLN1-600A Chapter 7: Appendix 114 of 116
Alarm Number Explanation:
The alarms are given in individual bits and are reflected in the alarm number. The alarm number is
only used to drive a pop-up message and will probably not be very useful to you. If you decide to use
the alarm number instead of reading the individual alarm bits then the related values are shown below:
N11:74 Value Alarm Descriptions
0= NO ALARM
1= HOPPER 1 Out of Material 1
2= HOPPER 2 Out of Material 2
3= HOPPER 3 Out of Material 3
4= HOPPER 4 Out of Material 4
5= HOPPER 5 Out of Material 5
6= HOPPER 6 Out of Material 6
7= POWER INTERRUPTION while metering a Batch
8= PLC BATTER LOW Check PLC and Configure the Blender
9= PLC MODULE LOADED Turn Off Unit,Remove Module, then Configure the Blender
10= MAX HOPPER WEIGHT EXCEEDED. CHECK BATCH SIZE
11= CALIBRATION ERROR. Clean out weigh hopper and check calibration
15= HOPPER 1 Low Level
16= HOPPER 2 Low Level
17= HOPPER 3 Low Level
18= HOPPER 4 Low Level
19= HOPPER 5 Low Level
20= HOPPER 6 Low Level
21= HOPPER 7 Low Level
22= HOPPER 8 Low Level
23= HOPPER 7 Out of Material
24= HOPPER 8 Out of Material
FIXED DECIMAL EXPLANATION
All weight values and recipe values use fixed decimal. This must be taken into consideration when
writing or reading values. If you see “xxx.xxx” above this means the data is in fixed decimal and must
be scaled when reading or writing. A decimal is shown next to each item to represent the format.
BLN1-600A Chapter 7: Appendix 115 of 116
WRITING RECIPE EXPLANATION
To write a recipe you must first write to the “temp recipe” value locations above. After this is
complete you should read the “accept recipe enabled” and the “recipe error” values. If you have a
recipe error then you should display the appropriate text. If the “accept recipe enabled” is high then
show a button that will then write to “accept recipe” bit. This will load in the recipe. You do not need
to check the sum of the recipe that they’ve entered. The blender will do that for you.
RECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH
The targets that are read are in lbs or kgs. When a batch is complete and dumped the blender will
toggle high the “print data now” bit. At this time you should then read the “actual displayed weights”
values and record them into a log or chart. If you are not getting the “print now” bit, then refer to the
blender manual to configure “print batch data”.
INVENTORY EXPLANATION
In order to keep track of very large numbers while accurately keeping track of small increments the
blender uses two numbers for each inventory value. One number is the “whole” portion of the
inventory and the other is the “decimal” portion of the inventory in 3 decimal places. Most people
choose to ignore the decimal portion, but it’s there to provide additional accuracy. An example is
given below:
Whole portion value: 12345
Decimal (or Fractional) portion value: 678
This would represent 12345.678 lbs or kgs.
• If you chose to write the recipe to the raw recipe locations you run the risk
of inadvertently entering the incorrect recipe. This is not recommended
because it will bypass all the checks that the blender makes before letting
you hit “accept new recipe”. Also if you chose to use the raw method then
you must add up the totals for your recipe and write that at the exact same
time that you write the other raw recipe values. You must also right the
batch size and recipe entry information or the blender might not make a
batch.
• WHEN THE BLENDER IS NOT RUNNING THE “TARGET” VALUES
GET SET TO “999999999” AND IN THE BEGINNING OF EACH BATCH
ALL ACTUAL VALUES GET SET TO “999999999” UNTIL THE
HOPPER FEEDS MATERIAL INTO THE NEW BATCH.
BLN1-600A Chapter 7: Appendix 116 of 116
7-6 Technical Assistance
Parts Department
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.
For immediate assistance, please contact:
North, Central and South America, 8am – 5pm CST +1 (800) 483-3919.
North America, emergencies after 5pm CST (847) 439-5855
Europe +48 22 390 9720
India/Middle East +91 21 35329112
Asia/Australia +86 512 8717 1919
Sales and Contracting Department
Our products are sold by a worldwide network of independent sales representatives. Contact
our Sales Department for the name of the sales representative nearest you.
Let us install your system. The Contract 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.
For assistance with your sales or system contracting needs please Call:
North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700
Monday–Friday, 8am–5pm CST
Europe +48 22 390 9720
India/Middle Ease +91 21 35329112
Asia/Australia +86 512 8717 1919
Facilities
ACS offers facilities around the world to service you no matter where you are located. For
more information visit us at www.acscorporate.com
United States:
ACS Schaumburg
1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804
ACS New Berlin
2900 S. 160th Street
New Berlin, WI 53151
Phone : +1 262 641 8600
Fax: + 1 262 641 8653
India/Middle East
ACS India
Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: +91 21 35329112
Fax: + 91 20 40147576
Asia/Australia:
ACS Suzhou
109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: +86 512 8717 1916
Europe:
ACS Warsaw
Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: +48 22 390 9724

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