ACS SGBD, BD, CSG User Manual
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!
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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!
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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, preoperational 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
Description/Explanation
Read Operators Manual. This equipment must be operated and
maintained by properly trained personnel. The information
contained within this manual must be read and understood prior to
operating this equipment.
Lifting point. Heavy load can fall and cause serious injury or
possible death. Lift equipment at designated points.
Disconnect before opening. Before servicing or maintaining the
machine be sure to disconnect the power and/or compressed air
source to avoid electrical shock and/or serious injury.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance operations
we recommend following the local standards for performing a
lock-out/tag-out procedure.
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 lowlevel 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.
• 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
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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
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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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