AEC OS Series Gravimetric Batch Blenders User Manual

OS/OA Series

Gravimetric Batch Blenders

(Standard & CE Models)

Operation, Installation and Service Manual

AEC/HydReclaim, Inc.

801 AEC Drive

Wood Dale, IL. 60191

Tel [630] 595-1060

Fax [630] 595-8924

www.aecinternet.com

Part No. A0553549 Bulletin No. HR1-605.3

4/1/02

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.

Parts and Service 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 [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

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 [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

Model # Serial #

Write down your Blender ________________ ________________

serial numbers here _____________ _____________

for future reference ________________ ________________

________________ ________________

________________ ________________

________________ ________________

________________ ________________

________________ ________________

________________ ________________

________________ ________________

AEC/HydReclaim is committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual

are subject to change without notice.

© Copyright AEC/HydReclaim, Inc. 2002

All rights reserved. Revised April 1, 2002

Part No. A0553549 Bulletin No. HR1-605A.3

ii

Table of Contents

Safety Considerations ...............................................................................5

Annex B Information................................................................................ 7

1 General Information .............................................................................8

1-1 Introduction ......................................................................................8

1-2 Equipment Function .........................................................................8

1-3 Accessories...................................................................................... 8

1-4 Customer Service.............................................................................8

1-5 Necessary Documents ..................................................................... 9

1-6 System Capabilities..........................................................................9

1-7 Equipment Covered by this Manual.................................................. 9

1-8 “OS” Series Weigh Blender Mechanical Features.......................... 10

1-9 “OS” Series Weigh Blender Control Features ................................11

1-10 OS (-E) Series Specifications...................................................... 12

1-11 OA (-E) Series Specifications....................................................... 12

1-12 Model OS/OA Blender System Component Description............... 13

1-13 Pneumatic Slide Gate Below Mixer (Optional)..............................22

2 Safety ...................................................................................................23

2-1 Work Rules..................................................................................... 23

2-2 Tools and Equipment Needed........................................................ 23

2-3 Mechanical Installation ...................................................................23

2-4 Safety Considerations .................................................................... 24

2-5 General Responsibility ...................................................................25

2-6 Operator Responsibility ..................................................................25

2-7 Maintenance Responsibility............................................................ 27

2-8 Safety .............................................................................................28

2-9 Electric Safety Interlock Switch (All Models) ..................................32

2-10 Air Pressure Safety Circuit ...........................................................32

3 Shipping Information .........................................................................34

3-1 Unpacking and Inspection ..............................................................34

3-2 In the Event of Shipping Damages ................................................. 34

3-3 If the Shipment is Not Complete.....................................................35

3-4 If the Shipment is Not Correct ........................................................36

3-5 Returns........................................................................................... 36

4 Installation ........................................................................................37

4-1 Chapter Description and Objectives ............................................... 37

4-2 Site Requirements..........................................................................37

4-3 Installation Overview ...................................................................... 41

4-4 Mechanical Installation ...................................................................41

4-5 Electrical Installation....................................................................... 42

4-6 Pneumatic Installation .................................................................... 43

4-7 Blender Set-up ...............................................................................44

iii

5 Operation .........................................................................................47

5-1 OS/OA Blender Sequence of Operation......................................... 47

5-2 Quick Start Procedure .................................................................... 47

5-3 Recipe Entry Formats..................................................................... 48

5-4 OS & OA Series Control System Menu Structure...........................51

5-5 Blender Calibration.........................................................................52

5-6 Controller Mode Setup ...................................................................53

5-7 Color Change ................................................................................. 54

5-8 Additional Operation Features........................................................56

5-9 Stroke Limiters for Metering Gates................................................. 82

6 Maintenance…………… ……………………………………………….83

6-1 Work Rules..................................................................................... 83

6-2 Maintaining Blenders...................................................................... 83

6-3 Control Setup .................................................................................84

6-4 Optimum OS & OA Series Blender Menu Structure .......................85

6-5 Mechanical ..................................................................................... 86

6-6 Electrical......................................................................................... 87

6-7 Pneumatic System Maintenance.................................................... 91

7 Troubleshooting ................................................................................92

7-1 Description and Objectives............................................................. 92

7-2 Common Controller Error Codes.................................................... 95

8 Blender Options ................................................................................96

9 Spare Parts ........................................................................................97

9-1 Recommended Spare Parts List..................................................... 97

9-2 Model OS/OA Blender System Component Description............... 103

10 Technical Assistance.....................................................................110

10-1 Contact Information for Technical Assistance ............................110

10-2 Returned Material Policy ............................................................111

10-3 Warranty..................................................................................... 112

11 Safety Tag Information ...................................................................113

11-1 OS/OA Blender Safety Tags.......................................................113

11-2 Pushbutton and Keypad Tags .................................................... 114

11-3 Blender Identification (Serial Number) Tag ...............................115

12 Appendix ...........................................................................................116

12-1 Addendum Service Supervisor Information
12-2 Electrial Schematics
12-3 Pneumatic Schematic

iv

Safety Considerations

AEC equipment is designed to provide safe and reliable operation
when installed and operated within design specifications, following
national and local safety codes.

To avoid possible personal injury or equipment damage when
installing, operating, or maintaining this equipment, use good
judgment and follow these safe practices:

; Follow all SAFETY CODES.

; Wear SAFETY GLASSES and WORK GLOVES.

; Disconnect and/or lock out power before servicing or

maintaining the blender.

; Use care when LOADING, UNLOADING, RIGGING, or

MOVING this equipment.

; Operate this equipment within design specifications.

; UNPLUG OR OPEN, TAG, and LOCK ALL DISCONNECT

DEVICES before working on equipment. You should remove
the fuses and carry them with you.

; GROUND your equipment properly before applying power.

; Use extreme caution when working with your equipment.

Keep body parts, tools, clothing, and debris away from
vacuum inlets and moving parts.

; Do not jump or bypass any electrical safety components.

; Do not restore power until you remove all tools, test

equipment, etc., and the blender and related equipment are
fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the

information in this manual should work on this equipment.

Page 5 of 118

AEC/HydReclaim

“OS-E” Series Blenders

This blender is manufactured by ACS, Inc. at the ACS-Wood Dale facility:

ACS, Inc.

801 AEC Drive

Wood Dale, IL 60191

Phone: [phone]

Fax: [phone]

The equipment is distributed in Europe by our European facility:

ACS-EUROPE

Daniels Industrial Estate

BATH ROAD

Stroud, Gloucestershire, England

GL5 3TJ

Phone: [phone]

Fax: [phone]

Page 6 of 118

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: 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: 120/1/60 or 220/1/50/60 (Verify on serial number

tag)

13.

Earth ground type: TN (system has one point directly earthed through

a protective conductor)

14.

Power supply should include a neutral power connection.

15.

Over-current protection is supplied in the blender, but additional protection should be
supplied by the user.

16.

The plug on the power cord serves as the electrical disconnect device.

17.

Unit is not equipped with three-phase motors.

18.

N/A

19.

Blender is not equipped with local lighting.

20.

Functional identification

21.

Blender is equipped with a CE mark

22.

Blender is supplied with an operating manual in the language of the destination country.

23.

Cable support may be required for power cord, depending on final installation.

24.

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.

25.

Doors can be opened with a screwdriver, but no keys are required.

26.

Two-hand control is not required or provided.

27.

All blenders should be moved around and set in a place with a lift truck or equivalent.

28.

There are no frequent repetitive cycles that require manual controlrepetitive functions
are automatic while the blender is operating.

29.

An inspection report detailing the functional test is included with the blender.

30.

The machine is not equipped with cableless controls.

31.

Color-coded (harmonized) power cord is sufficient for proper installation.

Page 7 of 118

1 General Information

1-1 Introduction

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

1-2 Equipment Function

All OS/OA 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.

1-3 Accessories

AEC/HydReclaim offers a variety of standard options for blenders including
floor stands, RAM feeders, loading equipment, etc. All accessories are
designed and manufactured by AEC, Inc. to ensure proper results for your
application.

1-4 Customer Service

The intent of this manual is to familiarize the operator and maintenance
personnel with this equipment 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.

NOTICE:

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.

Page 8 of 118

1-5 Necessary Documents

The documents listed below are necessary for proper installation, operation and
maintenance of OS/OA Series Gravimetric Batch Blenders. You can obtain
additional copies from the AEC/HydReclaim Service Department at AEC, Inc or
ACS Europe.

Make sure that appropriate personnel get familiar with these documents:

This Operation, Installation, and Service manual

•

Electrical schematic and connection diagrams

•

Pneumatic circuit drawing

•

Electric motor and controller information sheets (if equipped)

•

Operation and Installation manuals for supplied options and

•

accessories

1-6 System Capabilities

Blending systems are as varied as the applications that they service. This
equipment is intended to blend the materials(s) specified at the time of purchase
at specific rates.

1-7 Equipment Covered by this Manual

OS Blenders OA Blenders

• OS-007(E) • OA-002(E)

• OS-014(E) • OA-012(E)

• OS-030(E) • OA-030(E)

• OS-070(E) • OA-060(E)

• OS-080(E)

• OS-100(E)

Note: (E) Denotes “CE” models, including 220/1/50

Operation and CE mark

Page 9 of 118

1-8 “OS” Series Weigh Blender Mechanical Features

OS Slide Gate Blender OA Auger Blender

Efficient Opti-Mixer® and “HC” mixer designs promote homogeneity

•

Exclusive diamond design slide gate metering assemblies meter a large range for

•

free flowing pellet materials (OS Series)
Slide gate stroke limiting restrictors provided for accurate metering of minor

•

ingredients (OS Series)
Precision auger metering (standard on OA Series, optional on OS)

•

Electro-polished 304 SS stainless steel weighing and blending components

•

Precision 1/10% span accurate cantilever load cell weighing system

•

Removable stainless steel weigh hopper

•

Removable stainless steel mixer agitator and mixer wrap

•

Mild steel material supply hoppers with clean-out doors and material drains

•

Compressed air hose with nozzle for clean-out

•

Safety-interlocked system shuts off compressed air and electricity if mixer is opened

•

Page 10 of 118

1-9 “OS” Series Weigh Blender Control Features

LCD display operator control panel with two line display and 10’ cable

•

Target vs. actual set point verification

•

Inventory accumulation for all ingredients

•

Audible alarm

•

Auxiliary alarm contact

•

100 recipe storage book

•

Three (3) types of recipe entry procedures available:

•

EZ mode

9

metered as a percentage of the virgin material.

Percentage mode

9

of the overall batch.

Parts mode

9

each other within the batch

Full control diagnostics

•

Parallel printer and RS-485 communications ports

•

(up to 6-component) recipe entry. Color and additives are

recipe entry. Ingredients are metered as a percentage

recipe entry (i.e. 500:1) Ingredients are metered as a ratio to

Page 11 of 118

1-10 OS (-E) Series Specifications

OS Series Specifications OS-007 OS-014 OS-030 OS-070 OS-080 OS-100

Number of materials blended 4 2 to 6 2 to 6 2 to 6 2 to 6 2 to 5

Slide gate (adjustable, in (mm)) square 2 (50) 2 (50) 2.5 (63) 3 (76) 3 (76) 4 (101)

Supply hopper capacity, ft³ (l) 0.75 (21) 2 (56) 3 (85) 3.9 (110) 3.9 (110) 3.9 (110)

Weigh hopper capacity ft³ (l) 0.12 (3.4) 0.4 (11) 0.65 (18) 1.4 (39) 1.4 (39) 1.4 (39)

Typical batch size, lbs. (kg) 3 (1.3) 8 (3.6) 15 (6.8) 35 (16) 35 (16) 35 (16)

Mixer capacity, lbs. (kg) 6 (2.7) 20 (9) 30 (13.6) 75 (34) 75 (34) 75 (34)

Mixer motor size, HP (kW)

Mixer speed, rpm 30 16 22 22 22 22

Load cell capacity (2 per blender) 2 kg ea. 5 kg ea. 10 kg ea. 20 kg ea. 20 kg ea. 20 kg ea.

Blended material discharge opening, in (mm) 3 (76) 3 (76) 4 (101) 4 (101) 4 (101) 4 (101)

Maximum blending rate (approx.), lbs/hr (kg/hr) 350 (159) 700 (318) 1500(680) 3500 (1590) 4000 (1820) 5000 (2270)

Weight of machine (approx.), lbs (kg) 145 (66) 200 (91) 400 (185) 600 (275) 600 (275) 600 (275)

Shipping weight (approx.), lbs (kg) 200 (91) 400 (185) 600 (275) 850 (390) 850 (390) 850 (390)

1

/6 (.12)

1

/6 (.12)

1

/2 (.37)

1

/2 (.37)

1

/2 (.37)

1

/2 (.37)

1-11 OA (-E) Series Specifications

OA Series Specifications OA-002 OA-012 OA-030 OA-060

Number of materials blended 2 to 4 2 to 6

Supply hopper capacity, ft³ (l) 0.25 (7) 1.1 (31)

Weigh hopper capacity, ft³ (l) 0.08 (2.2) 0.14 (4)

Typical batch size, lbs (kg) 3 (1.3) 5 (2.3)

Mixer type

Mixer capacity, lbs (kg) 6 (2.7) 10 (4.5)

Mixer motor size, HP (kW)

Mixer speed, rpm 30 50

Load cell capacity (1 per blender except OA-002) 2 @ 2 kg 5 kg

Blended material discharge opening 3 (76) 3 (76)

Maximum blending rate (approx.), lbs./hr. (kg/hr) 100 (45) 600 (270)

Weight of machine (approx.), lbs (kg) 145 (7.0) 200 (91)

Shipping weight (approx.), lbs (kg) 200 (91) 400 (185)

Opti-mixer “HC”

1

/6 (.12)

1

/4 (.18)

2 to 6

1.9 - 2.75 (54 – 77)

0.6 (16)

20 (9)

40 (18)

1

/2 (.37)

50

10 kg

3 (76)

1500 (680)

450 (205)

650 (295)

2 to 6

1.4 (40)

50 (22)

100 (45)

1 (.746)

50

20 kg

4 (101)

3000 (1360)

600 (275)

850 (390)

Note: OS/OA features and specifications are subject to change without notice.

Page 12 of 118

1-12 Model OS/OA Blender System Component Description

This section describes the various components of the blending system. The
HydReclaim OS/OA blending system is made up of the following components:

1-12-1 Material Supply Hoppers

1-12-2 Slide Gate Metering Assemblies (OS Series)

1-12-3 Auger Metering Assemblies (OA Series)

1-12-4 Weigh Hopper

1-12-5 Weigh Hopper Dump Valve

1-12-6 Mix Chamber

1-12-7 Operator Control Panel

OS OA

(with optional Opti-Mixer™)

Page 13 of 118

1-12-1 Material Supply Hoppers




The material supply hoppers are located on top of the blender frame.
These hoppers store a supply of material for the individual metering
devices. They are sized based on the total throughput of the blender.

The OS/OA blending system does not include any level indication
devices on the unit. Optional low-level sensors and low-level alarm
panels 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.

Each hopper is equipped with a sight glass and/or access door.

HINGED POLYCARBONATE
ACCESS DOOR

DOOR LATCH

PNEUMATIC SAFETY SWITCH
(IF EQUIPPED- OLDER
MODELS ONLY)

SIGHT GLASS (IF EQUIPPED)

DRAIN PORT WITH PLUG

Typical Material Supply Hoppers

Page 14 of 118

1-12-2 Slide Gate Metering Assemblies (OS Series)

Air operated slide gates are provided to meter the majority of pellet
ingredients on the OS blenders.

Important!

The metering range assumes
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.

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.

1

” diameter free-flowing plastic

/8

The unique HydReclaim 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.

WARNING!

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 HydReclaim blender, including
all OS/OA Series models. Failure to do so may result in
serious injury.

Page 15 of 118

Important!

Each of the diamond gate air cylinders is actuated by a solenoid valve,
which are controlled by the blender.

When the solenoid valve is energized, it opens the metering valve
cylinder. When the solenoid valve is de-energized, it closes the
metering valve cylinder.

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.

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

can occur!

an overflow of the weigh hopper

Page 16 of 118

1-12-3 Auger Metering Assemblies (OA Series)

OA Series blenders are equipped with auger metering units, including
the following components:

Cast aluminum feeder bodies

•

Cast aluminum motor mounts

•

Heavy-duty AC gear motors (Optional DC drives are available)

•

Drain spouts with slide gate shut-off

•

Machined steel auger

•

Cast aluminum auger housing

•

Spun aluminum material supply hoppers

•

Cover with cut-out for Whitlock SRC vacuum receivers

•

Optimum OA Series available with a Choice of Mixers

OA with standard “HC” mixer OA with optional Opti-Mixer®

Multiple regrinds and Pellets and one

more difficult materials

free-flowing regrind

Page 17 of 118

1-12-4 Weigh Hopper

The weigh hopper on the OS/OA blender is used to weigh each batch
of material, and includes an air-operated discharge valve. After the
batch is weighed and the level sensor in the lower mix section is
uncovered, the valve will open and discharge the batch into the mixer
with the existing blended material. The discharge valve is also
provided with a quick disconnect so the weigh hopper can be removed
for cleaning.

On an OS blender, the weigh hopper rests on each side on a precision
cantilever load cell. To remove the weigh hopper, lift the hopper from
the bottom, hold the discharge valve 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.

Important!

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.

LOCATING TABS

LOAD CELL

AIR CYLINDER

WEIGH HOPPER

DISCHARGE VALVE

LOAD CELL

The OA-HC style weigh hopper is bolted in place, and is generally not
removed.

Page 18 of 118

1-12-5 Weigh Hopper Discharge Valve

The weigh hopper discharge valve holds the material until it is dumped
into the mixing section. The cylinder is actuated by a solenoid in the
valve stack on the rear of the blender.

In looking at the pneumatic circuit, you can see that the air regulator
controls the flow of air to the valve stack. 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.

CAUTION!

The pneumatic system used on the OS/OA, like all pneumatic
systems, is highly sensitive to dirty, wet or contaminated air. If
dirt, water, or any other air-borne contaminates enter the system,
the components could be damaged and injury to the operator
could result.

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.

A proper air supply must be supplied to the blender.

Page 19 of 118

1-12-6 Mix Chamber

WARNING!

All of the HydReclaim batch blenders are equipped with an integral
mix chamber. The mix chamber holds multiple batches of material so
any variations in a batch are averaged over time.

1-12-6-1 Opti-Mixer™

The Opti-mixer™ is designed to provide bi-directional
mixing action and can be easily taken apart for cleaning.
This design is standard on all OS blenders, and is optional
on all OA models.

1-12-6-2 “HC” Mixer

The “HC” Mixer features an open wheel design and is best
used for multiple regrind materials. It is standard on all OA
models.

Never reach into the mix section of the blender without
disconnecting the power or air supply.
Serious injury can result from getting your hand caught in the
rotating mixer!

Page 20 of 118

1-12-7 Operator Control Panel

The operator control panel includes an 8 foot (2.4 m) cable and can
be remote mounted adjacent to the blender. The panel can be
unplugged and removed if necessary.

The controller includes an embedded computer. 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 and keypad menu format is very simple. After installation
and setup, simply enter in the recipe and start the blender.

If it is desired to have a local display and control of the blender closer
to a remote operator station, an optional RS485 remote control panel
(RCP) is available.

Adjust component settings in EZ recipe mode

“Backup” key

“Abort” cycle key

“Enter” key

Note:

The panel keypad on your unit may be slightly different than shown.

“Start” blend cycle key

Stop at “End of cycle” key

“Clear” key

Numeric entry keys

Page 21 of 118

1-13 Pneumatic Slide Gate Below Mixer (Optional)

The OS/OA 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.

Mixer Slide Gate Switch Positions

AUTO

OPEN Slide gate open all the time

CLOSE Slide gate closed all the time

Slide gate closes when mixer starts and
opens when mixer stops

TYPICAL CENTRAL BLENDER LAYOUT

Blender

Pneumatic Slide Gate Below Mixer

Surge Bin

Take-off Compartment

Floor Stand

Page 22 of 118

Safety 2

2-1 Work Rules

Install, operate, and maintain this equipment according to applicable work and
safety codes for your location. This includes OSHA, CE, NEC, CSA, SPI, and
many other local, national, and international regulations. Obey these specific
work rules:

 Read and follow the instructions in this manual before installing, operating, or

maintaining any equipment. Additional copies are available from AEC, Inc.

 Only qualified persons should work on, or with, this equipment.

 Work only with approved tools and devices.

 Disconnect and lock out power while working on this equipment.

2-2 Tools and Equipment Needed

You’ll need the following:

Hand tools

•

Fork lift or overhead lift

•

Wire, conduit, and fittings for wiring runs (if receptacle is not already in

•

place)

Mounting bolts with nuts and washers

•

Compressed air tubing and fittings

•

2-3 Mechanical Installation

Blenders may be mounted on the machine, a stand, or a mezzanine. Be sure it is
securely attached and additional bracing is used if necessary. The sections on
the following pages explain general installation rules.

Read manual thoroughly before installing
blender.

Use approved safety straps or chains to lift the
blender at the marked lifting points.

Page 23 of 118

2-4 Safety Considerations

The terms
meanings in this manual. See Section 11 for a complete list of specific safety

warning information.

NOTICE, CAUTION, WARNING,

NOTICE

A
indirectly related to the safety of personnel or protection of property.

CAUTION

A
avoided, may result in minor or moderate injury.

WARNING

A
avoided could result in death or serious injury.

DANGER

A
avoided, will result in death or serious injury. This word will be limited
to the most serious situation(s).

The term
could result, or provides additional information to make a step or
procedure easier to understand. Disregarding information marked

IMPORTANT

is used to indicate a statement of company policy directly or

indicates a potentially hazardous situation which, if not

indicates a potentially hazardous situation which, if not

indicates an imminently hazardous situation which, if not

IMPORTANT

would not be likely to cause personal injury.

emphasizes areas where equipment damage

and

DANGER

have specific

REPORTING A SAFETY DEFECT

NOTE:

If you believe that your equipment has a defect which could cause

injury, you should immediately discontinue its use and inform AEC, Inc.,
at our address listed in this manual.

The principle factors which can result in injury are:

1. Failure to follow proper operating and clean-out procedures, i.e.
lockout/tagout.

2. Failure to maintain a clean and safe working environment.

Page 24 of 118

2-5 General Responsibility

NO MATTER WHO YOU ARE…

Safety is important. Owners, operators, and maintenance personnel must realize
that every day, safety is a vital aspect of their jobs.

If your main concern is loss of productivity, remember this:

affected in a negative way following an accident.

the reasons, which can affect your production:

Loss of a skilled operator (temporarily or permanently)

•

Breakdown of shop morale

•

Costly damage to equipment

•

Down-time

•

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.

The following are some of

Production is always

2-6 Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator
usually has the most daily contact with the blender 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.

ONLY YOU

safe and what is not. It is often the “just once” that an operator reaches into a
blender to remove material and it results in serious injury.

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.

can make safety work for you by constantly thinking about what is

Page 25 of 118

REMEMBER:

NEVER

•

location.

NEVER

•

training and first reading and understanding this manual.

NEVER

•

running!

Before you start the blender check the following:

•

If your blender has been inoperative or unattended, check all settings

•

before starting the unit.

At the beginning of your shift and after breaks, verify that the controls

•

and other auxiliary equipment are functioning properly.

place your hands or any part of your body in any dangerous

operate, service, or adjust the blender without appropriate

try to pull material out of the blender with your hands while it is

Remove all tools from the blender;

•

Be sure no objects (tools, nuts, bolts, clamps, bars) are

•

laying in the metering or mixing area;

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.

Report the following occurrences

•

unsafe operation or condition

•

unusual blender action

•

leakage

•

improper maintenance

•

NEVER

•

stand or sit where you could slip or stumble into the blender

IMMEDIATELY:

while working on it.

DO NOT

•

wear loose clothing or jewelry, which can be caught while

working on a blender. Also 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

•

OFF

the

position, or unplug it from the power source.

Page 26 of 118

2-7 Maintenance Responsibility

Safety is essential to the good health of both operator and machine. If you are a
maintenance worker, you must make safety a priority in order to effectively repair
and maintain equipment.

BEFORE REMOVING, ADJUSTING, OR REPLACING PARTS ON A MACHINE,
REMEMBER TO DO THE FOLLOWING:

BLEED

•

Section of this manual.)

TURN OFF

•

machine.

DISCONNECT AND LOCK OUT

•

warning tags to the disconnect switch and air shutoff valve.

When you need to perform maintenance or repair work on a blender above floor
level, use a solid platform or a hydraulic elevator. If there is a permanently
installed catwalk on your blender, use it. The work platform should have secure
footing and a place for tools and parts.
work from ladders.

all air pressure from system components (refer to the Maintenance

all air and electric supplies and all accessory equipment at the

electrical and pneumatic power, and attach

DO NOT

climb on blenders, machines, or

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 of electrical apparatus, electrical
component enclosures, and the blender frame are correctly connected to earth
ground with an electrical conductor that complies with current codes. Install in
accordance with national and local codes, which apply.

When you have completed the repair or maintenance procedure, check your work,
remove your tools, rigging, and handling equipment.

Do not restore power to the blender until all persons are clear of the area. Start
and run the blender until you are sure all parts are functioning correctly.

BEFORE

and safety devices are in place and functioning properly.

you turn the blender over to the operator for production, verify all guards

Page 27 of 118

2-8 Safety

2-8-1 Description and Objectives

2-8-2 Safety Circuit Standards

This section includes information on safety devices and procedures that
are inherent to the OS/OA blending system. 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
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:

Identify and locate specific safety devices.

•

Understand the proper use of the safety devices provided.

•

Describe the function of the safety devices.

•

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 the 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 into the
design of the OS/OA blending system; 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.

Page 28 of 118

2-8-3 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

safety switch fails, the motor should not be able to run.

. For example, if a safety switch is guarding a motor, and the

2-8-4 Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The
safety devices that are utilized on HydReclaim OS/OA models are
primarily concerned with the pneumatics and electrical power
disconnection, and the disabling of moving parts that may need to be
accessed during the normal operation of the machine.

Some of the safety devices utilize a manual activator. This is the method
of initiating the safety lock out. This may be in the form of a plug,
disconnect plug, lever or a handle. Within this lockable handle, there may
be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.

WARNING!

Always disconnect and lockout all electrical power and pneumatic
(i.e. compressed air) sources prior to servicing or cleaning any
HydReclaim blender, including all OS/OA units. Failure to do so
may result in serious injury.
At no time must
plug, other than the person who installed the lockout or who
unplugged the twist plug.

anyone

remove the lockout or reconnect the twist

Page 29 of 118