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Sterling Allen-Bradley 015, Instruction Manual

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Sterling Allen-Bradley 015 Instruction Manual Download Page 1

 
 

 
________________________________

 

 

Continuous Loss-in-Weight Blenders  

with 

Allen-Bradley SLC 5/04 Programmable Controller 

and 

PanelView 600 Touch Screen Interface 

 
 
 
 
 
 

 

 

 

 

 

 

Part Number:  882.092698.00 

 

 

    Bulletin 

Number: 

BF3-615 

 

 

    Effective: 

 

9/1/08 

 

 
 
 
 
 

Write Down Your Serial Numbers Here For Future Reference: 
 
_________________________   _________________________ 
 
_________________________   _________________________ 
 
_________________________   _________________________ 

 
We are committed to a continuing program of product improvement. 
Specifications, appearance, and dimensions described in this manual are subject to change without notice. 

 

DCN No. ____________ 
© Copyright 2008 
All rights reserved. 

Summary of Contents for Allen-Bradley 015

Page 1: ...ite Down Your Serial Numbers Here For Future Reference _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No ____________ Co...

Page 2: ...s 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...

Page 3: ...al 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...

Page 4: ...s components 13 Mechanical features 13 Controller features 13 Electrical features 13 Blender system component description 14 2 4 Options 19 2 5 Safety devices and interlocks 20 CHAPTER 3 INSTALLATION 22 3 1 Uncrating the equipment 22 3 2 Rigging and placing the unit 22 Site requirements 23 Mounting configuration 23 3 3 Electrical installation 26 3 4 Pneumatic installation 27 3 5 Overall installati...

Page 5: ...lenders v MAINTENANCE 52 Preventative maintenance schedule 52 APPENDIX 54 6 1 Warranty and spare parts 54 Annex B information 55 6 2 Addendum Service supervisor information 55 Programmable settings 56 6 3 Technical assistance 63 ...

Page 6: ...and mechanical controls in addition to information for operating the unit safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your Continuous Loss in Weight Blender provides excellent long service The Troublesho...

Page 7: ... in Weight Blender Safety Tags Tag Description Tag Description Pinch Point Slide Gate Read Operation Installation Manual Shear Point Rotating Mixer or Agitator Earth Ground High Voltage Inside Enclosure PE Protected Earth Ground Shear Hazard Rotating Auger Lifting Point ...

Page 8: ...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 b...

Page 9: ...e personnel must realize that safety is always a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An ef...

Page 10: ...R try to pull material out of the blender with your hands while it is running Before you start the blender check the following o Remove all tools from the unit o Be sure no objects tools nuts bolts clamps bars are laying in the metering or mixing area If your blender has been inoperative or unattended check all settings before starting the unit At the beginning of your shift and after breaks verif...

Page 11: ...re 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 a...

Page 12: ...cription All blenders are designed to blend plastic pellets and regrind and supply the blended material to the extruder The standard system is not designed to blend powder or any other no free flowing materials Consult the factory if your future process requirements require the addition of these materials Accessories The manufacturer offers a variety of options for these blending systems including...

Page 13: ...system Yasakawa GPD 205 variable frequency drive VFD system with hp inverter duty brushless AC motors Motor drive panel NEMA enclosure Machine mount spool flange with drain Hopper lids arranged for manufacturer and non manufacturer receivers and loaders Controller Features Color Allen Bradley PanelView 600 color touch screen o Easy menu driven format o Serial printer port o Recipe storage book o I...

Page 14: ...low weigh hopper Control panel Motor drive panel OPTIONAL Quick color change kit Figure 2 Continuous Blender Assembly Ingredient Supply Re fill Hoppers The ingredient supply re fill hoppers are located on top of the blender frame Their purpose is to provide a supply of material to the individual ingredient weigh hoppers on demand The hoppers are equipped with an air operated discharge valve that i...

Page 15: ...mbly consists of a conical mass flow weigh hopper a precision load cell and a discharge tube disc seal A mass flow weigh hopper is a steep degree conical hopper with vertical side walls with a discharge tube on the bottom Each weigh hopper is sized to the blender ingredient metering requirements This assembly is responsible for weighing the material ingredients as they are metered out by the meter...

Page 16: ...he calculated rate The mass flow weigh hopper design allows more range of the load cell to be used for actually weighing the material and eliminates dynamic drive movement and vibrations from affecting the load cell readings Figure 3 Metering Auger Components Cascade Material Chute The cascade material chute is a rectangular conduit in which all the metering augers discharge The materials are casc...

Page 17: ...d to match the learned processing rate This method of operation provides very accurate slave in of the blender to the processing rate and eliminates the need for a mixing hopper The lower common weigh hopper is also equipped with a high level proximity level sensor to allow manually adjusted volumetric operation of the blender in the event of computer failure Figure 4 Weigh Hopper Assembly Note Th...

Page 18: ...blender The standard panel contains Yaskawa GPD 205 variable frequency motor drives a power supply and manual volumetric backup system wiring components The motor drives on the blender are standard off the shelf drives and are readily available from Yaskawa distributors and the manufacturer Power cords to each drive motor are equipped with plugs to facilitate auger removal and motor replacement if...

Page 19: ...t alarm panel with its own lights horn and silence button Supply hopper lids for non ACS supplied vacuum receivers loaders Agitated straight wall regrind supply weigh hoppers for regrind material Compressed air loader for low percentage additives Ethernet communication module Remote Display Allows control of blender from a second location up to 50 feet 15 meters away The remote display can be loca...

Page 20: ...Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards int...

Page 21: ...anyone other than the person who installed the lockout or unplugged a twist plug remove the lockout or reconnect the twist plug Pluggable Line Cord This line power cord allows the operator or maintenance personnel to unplug the blending system from its power source and tag it out This plug may be tagged with any number of approved electrical lockout tags These tags are available at most electrical...

Page 22: ...ifting Eyebolt Position on Blender Caution Remove hoppers if necessary to prevent damage 3 Lift blender until strap is taut 4 Remove bolts attaching bottom of blender to shipping skid 5 Raise the blender slowly 3 2 Rigging and Placing the Unit It is the intent of this section to familiarize the reader with the proper site requirements and installation procedures of the continuous loss in weight bl...

Page 23: ...and the loading system installed Note While in operation the continuous loss in weight blender applies horizontal and vertical pressures to the mounting flange The vacuum system will cause some shaking due to the dynamics of the conveying operation Note If there is a question as to the mechanical stability of a mounting flange the appropriate reinforcements and lateral supports must be provided to...

Page 24: ...to vibration the weigh hoppers will tend to remain stationary due to the laws of physics dealing with inertia This causes the load cells to output erroneous weight signals Note While in operation the blender applies both horizontal and vertical pressures to the mezzanine mount location Second verify ALL clearances to other equipment and structures Insure motors hoppers and control panels have prop...

Page 25: ...ly diagram provided with each blender Note Auger assemblies require a minimum of 24 inches of clearance for proper servicing and cleaning Insure the chosen location for the blending system is adequately away from high traffic aisles Insure that normal day to day operations will not place the blending system at risk of damage Once a proper location has been chosen securely fasten the blender floor ...

Page 26: ...pply voltage If supplied they are rated for the load required by the blending system no other equipment should be connected to the transformer The additional equipment may induce noise into the power circuit to the blender as well as possibly overload the transformer The power transformer wiring and mounting is the responsibility of the customer If company or local codes require fusing or disconne...

Page 27: ... the customer s responsibility to ensure that the air is CLEAN DRY LUBRICATED Any component failures due to airborne contaminants will not be subject to warranty consideration The working range of the air pressure is from 40 60 PSI PSI lower than 40 may result in shutoff valve failure PSI greater than 60 may result in damage to the plunger cones in the re fill hoppers A 5 micron filter is recommen...

Page 28: ... bottom of the weigh hopper Align the discharge tube on the weigh hopper to be centered in the lower frame opening over the feeder assembly Use caution in tightening the bolts Adjust the gap to 0 040 5 Hook the manual mode level sensor bracket over the lower mass flow weigh hopper on the bottom of the blender Ensure that the cord is not binding on anything that would affect the accuracy of the wei...

Page 29: ...over ranged by excessive loading on the weigh hopper The setting for the load cell stop is forty thousandths of an inch maximum 040 This should be set by a feeler thickness gauge with the weigh hopper empty If a feeler gauge is not available the weigh hopper should be filled with the material that is to be blended and the stop adjusted so there is just a very small gap a couple of sheets of notebo...

Page 30: ... with the proper water trap and lubrication unit if required Verify that 60 psi 4 14 bar of clean dry compressed air is supplied to the blender Note Again make sure that proper air supply connections are made to the blender as dirty contaminated wet air can damage blender components and can quickly cause poor performance and accuracy Note Make sure that the blender is supplied with clean dry 60 ps...

Page 31: ...r the weight in each of the ingredient weigh hoppers and the lower mass flow weigh hopper As the load cells are reading the actual material weight loss that is removed from the weigh hoppers by the feeders or the extruder the proper calibration of these load cells is essential for the correct operation of the blender This calibration must be performed upon initial installation and startup of the b...

Page 32: ...pacity of the load cell The standard load cell used on these blenders have a span accuracy of 1 10th The maximum capacity of each load cell is clearly marked on the fixed top of the load cell This value will be indicated in kgs 2 2 lbs 1 kg Figure 11 Blender Calibration Weight Scale Calibration During the initial setup of the blenders the feeder units will need to be setup Most of these items shou...

Page 33: ... Blenders Chapter 3 Installation 33 Touch the ACS Group logo in the upper left hand corner You will be prompted to enter a password it is 5413 You will see the Password Accepted screen now press OK Touch the Calibration button ...

Page 34: ...ouch Set Cal Wt 4 Repeat for all Hoppers including Mass Flow 5 Touch done when complete You can also check the calibration by looking at the in LBS box and hanging your calibration weight on the weigh hopper to be checked Feeder Calibration This section will explain how to calibrate the feeders on your OL blender This must be done on initial startup and whenever material is change and bulk density...

Page 35: ...Continuous Loss in Weight Blenders Chapter 3 Installation 35 Touch the ACS Group Logo Then enter password 5413 Touch the OK button Touch the Calibration button ...

Page 36: ... It is possible to forgo calibration after the initial calibration is complete if you note down the calibration values listed in the CAL VALUES box If you are changing back to a calibrated resin simply touch the box under Cal Values and enter the appropriate number Setting Hopper Size As the blenders are provided in several sizes and output ranges the system will need to know what size all of the ...

Page 37: ...Approximate Hopper Capacity 35 lbs cu ft 9 7 12 14 14 18 20 40 24 60 Above lists standard sizes and can vary depending on the blender requirements and rates to be blended Larger hopper sizes are available on custom order Setting hopper size Touch the ACS Group logo and enter password 5413 Touch the OK button ...

Page 38: ... Hopper Setup Touch the box next to the hopper number that you want to change and enter weight value Setting Passwords There are three levels of password security for the control system User factory set to 5413 Service ACS only cannot be changed factory set to 3145348 ...

Page 39: ...Continuous Loss in Weight Blenders Chapter 3 Installation 39 To change a password proceed as follows Touch the ACS Group logo Enter password and touch OK Touch User Password ...

Page 40: ...ng re filled in the allotted time This would be caused by the supply hoppers not be kept full Check the loading system No material This means the weigh hopper is empty Load cell Failure The controller is not properly reading the load cell Check the load cell Load cell over ma x The maximum weight limit on the load cell is exceeded Check weigh hopper size and material bulk density Extruder No Flow ...

Page 41: ...Continuous Loss in Weight Blenders Chapter 3 Installation 41 First you must get to the Alarm Setup Page To do this Touch the ACS Group logo Enter the password and touch OK Touch Alarm Setup ...

Page 42: ...t Pop ups enabled means the alarms will be shown on the screen Select Pop ups disabled if you don t want to see the alarms on the screen Extruder flow alarm and Blender cannot keep up alarm can be enabled or disabled according to costumer requirements Communications All Allen Bradley Loss in weight blenders can be setup to communicate to a host via Ethernet an optional Ethernet module must be purc...

Page 43: ...Continuous Loss in Weight Blenders Chapter 3 Installation 43 Setting Blender for English or Metric Touch the ACS Group logo Enter the password and touch OK Touch Units ...

Page 44: ... Touch the box that says English Units to toggle between English and Metric Note you must re calibrate the blender and reset the inventory values if you change this value How to use FIFO Diagnostics First you must get to the FIFO screen Touch the ACS Group logo ...

Page 45: ...Continuous Loss in Weight Blenders Chapter 3 Installation 45 Enter the Password and touch OK Touch FIFO Diagnostics Select Mass Flow FIFO Data or Feeder FIFO Data ...

Page 46: ...n unstable system alarm you can check here for the problem This is a first in first in first out table It takes an average and gives you a percent differential If the steady flag is a 1 the hopper is steady If it is a 0 it is not steady This means that the percent differential is greater than what the value is set to on the advanced hopper page The mass flow FIFO works the same way only you have t...

Page 47: ...metering devices The metering units will start out at the maximum metering rate at speeds based on the feeder calibrations that were learned during the prior setup of the blender The blender will output the maximum rate that is achievable with the feeder sizes and the recipe percentage that is entered in the current recipe Each metering unit will meter its material out of its respective weigh hopp...

Page 48: ...If the extruder is slowed or stopped suddenly the blender will reach the high weight point in the lower mass flow hopper slow down and stop the metering devices so the weigh hopper will not overfill Manual Backup Control System Every continuous blender is equipped with a secondary manual backup control system This allows the blender to be switched over to manual operation In this mode the feeder s...

Page 49: ...controller on the continuous loss in weight blender utilizes a LCD touch screen display Figure 14 Typical Controller Display A typical menu entry is shown in the figure above Please refer to the blender menu structure shown in Figure 13 on the next page This figure shows a standard menu structure for the blending system ...

Page 50: ...Password Verify Password Alarm Setup No Material Flow Re fill to Long No Material Load cell Failure Load cell over max Extruder Flow Alarm Blender cannot keep up Pop ups enabled Network Info Recipe Book Page Save the running recipe to the book Delete a stored recipe Load a stored recipe Erase all stored recipes Modify the product ID for a stored recipe Return to the Recipe page Calibration Scale C...

Page 51: ...r 4 Operation 51 Setting a Recipe To set a recipe touch the hopper you want to change a keypad will pop up enter the desired percentage for the hopper Clean Out Touching the Clean Out button will take you to the page to manually run the motors ...

Page 52: ...e 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 all hoppers for any loose parts tighten them immediately Verify quality of compressed air supply Inspect all weigh hoppers for obstructions Every week Date By Date By Date By Date By Date By Date By Date By Date By D...

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

Page 54: ... kgs 150 kgs Load cells 724 00835 00 724 00836 00 724 00832 00 724 00839 00 61 1250 150KG Figure 64 Typical Allen Bradley Controller Main Parts List Description ALL MODELS 1 Allen Bradley SLC 500 CPU A0555198 2 24 VDC power supply A0563932 3 12 VDC power supply 739 00027 00 4 Alarm light Yellow strobe 24 VDC A0565889 5 Glass fuse 3 0 amp 115 volt A0542207 6 Ethernet module optional A0563939 7 Ethe...

Page 55: ...ion is supplied in the blender control panel but additional protection should be supplied by the user 15 The plug on the power cord serves as the electrical disconnect device 16 Unit is equipped with three phase motors driven by single phase motor drive cards 17 Functional identification 18 Cable support may be required for power cord depending on final installation 19 No one is required to be in ...

Page 56: ...ersonnel not extremely familiar with this blender controller should not use this section of the manual or program can be compromised Note Hidden programmable features and hidden menu pages should not be made available to floor operators These pages also include the Service Supervisor Information addendum located in this section Unauthorized changes to these factory settings by inexperienced operat...

Page 57: ...ee the following This is where you make adjustments to fine tune the blender s performance You will need to assess the FIFO page previously mentioned in the manually to decide what changes need to be made The following pages will show you the setup parameters and how to adjust them Advanced Hopper Options ...

Page 58: ...ep the auger from making rapid adjustments Re fill Percentage This is the level the hopper will go down to before re filling Learn Percentage This is the size of the snapshot previously mentioned Increasing this gives you better stability with materials that very in bulk density or do not flow consistently Decreasing this gives you faster updates on the FIFO page for materials that are relatively ...

Page 59: ...ize set point For material that varies in bulk density or does not flow consistently you may have to increase the limit Steady System Time Test This timer is used to determine whether or not to show the Steady System flag on the main control screen Rather than going in and out of stable the process must remain stable for the set time and then the Steady System will be shown PID Timer This is the a...

Page 60: ...um and maximum speed for the motor drives as a percentage The drives are not supposed to be run at less than 8 hertz and should not be run above 115 hertz Extruder RPM Options This gives you the option of having no extruder speed input writing the extruder speed to the blender through the Ethernet or using a proximity sensor on the end of the extruder screw ...

Page 61: ...extruder RPM can vary and still be considered steady With no extruder measurement the control always assumes a steady RPM Update Time for Prox Method in seconds This is how often the extruder speed updates from the prox Extrusion Control Options Feeder Setup This screen allows you to enter the maximum auger speed in Hertz ...

Page 62: ... caused by a blockage stopped motor etc No Flow Timer This is the amount of time used to measure the bit flow weight loss through a hopper to determine if an alarm is warranted No Flow Bits This is the amount of weight loss in a set amount of time No Flow Timer to sound an alarm Please contact the ACS Service Department with any other questions ...

Page 63: ...edicated to providing excellent customer service Service Department Call toll free 8 am 5 pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5 pm CST call 847 439 5655 We have a qualified Service Department ready to help Service contracts are also available for most of our products See www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8 am 5 pm CST Our products ar...

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