Sterling Allen-Bradley 060 User Manual

________________________________ Continuous Loss-in-Weight Blenders with Allen-Bradley SLC 5/04 Programmable Controller and PanelView 600 Touch S

Continuous Loss-in-Weight Blenders Chapter 1: Safety 10 Operator Responsibility The operator’s responsibility does not end with efficient production

Continuous Loss-in-Weight Blenders Chapter 1: Safety 11 • Clean the blender and surrounding area DAILY, and inspect the machine for loose, missing

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This m

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 13 2-3 Typical Features & Components Mechanical Features • Blender autom

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 14 Blender System Component Description This section describes the various comp

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 15 hoppers are not controlled nor read by the blender. Their existence is sole

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 16 Ingredient Metering/Transport Auger Assemblies Each metering auger assembly

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 17 Lower Mass Flow Weigh Hopper Assembly The lower mass flow weigh hopper, othe

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 18 PLC Control Panel The PLC control panel may be mounted on the side of the bl

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 19 2-4 Options The following is a list of options, which your blender may have

Continuous Loss-in-Weight Blenders ii Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage.

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 20 2-5 Safety Devices and Interlocks This section includes information on safet

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 21 Safety Device Lock-Outs Some safety devices disconnect electrical energy fro

Continuous Loss-in-Weight Blenders Chapter 3: Installation 22 Chapter 3: Installation 3-1 Uncrating the Equipment Continuous loss-in-weight blender

Continuous Loss-in-Weight Blenders Chapter 3: Installation 23 Site Requirements This section describes site requirements in detail. These requiremen

Continuous Loss-in-Weight Blenders Chapter 3: Installation 24 Note: Never weld on the blender’s frame, machine or mezzanine without first removing t

Continuous Loss-in-Weight Blenders Chapter 3: Installation 25 Note: Ensure that the feed tube angle is steep enough (60 degrees is recommended). No

Continuous Loss-in-Weight Blenders Chapter 3: Installation 26 Figure 8: Typical Layout for a floor mounted blender 3-3 Electrical Installation Th

Continuous Loss-in-Weight Blenders Chapter 3: Installation 27 3-4 Pneumatic Installation The blending system utilizes air pneumatics to perform the

Continuous Loss-in-Weight Blenders Chapter 3: Installation 28 3-5 Overall Installation (Summary) This installation procedure should be used as a ge

Continuous Loss-in-Weight Blenders Chapter 3: Installation 29 3-6 Set-up This section will discuss the mechanical setup and control system setup of

Continuous Loss-in-Weight Blenders iii Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMA n

Continuous Loss-in-Weight Blenders Chapter 3: Installation 30 Final Connections 1. Connect the blender to the appropriate power source. 2. Connect

Continuous Loss-in-Weight Blenders Chapter 3: Installation 31 Controller Setup This section describes the proper setup of the continuous loss-in-wei

Continuous Loss-in-Weight Blenders Chapter 3: Installation 32 will suffice. The weight will be in pounds, unless the blender is provided for metric

Continuous Loss-in-Weight Blenders Chapter 3: Installation 33 Touch the “ACS Group” logo in the upper left hand corner. You will be prompted to ent

Continuous Loss-in-Weight Blenders Chapter 3: Installation 34 Touch “Scale” button Find your calibration weight that shipped with the blender and l

Continuous Loss-in-Weight Blenders Chapter 3: Installation 35 Touch the “ACS Group” Logo. Then enter password “5413”. Touch the “OK” button. To

Continuous Loss-in-Weight Blenders Chapter 3: Installation 36 Touch “Feeder” button Feeder Calibration is carried out as follows

Continuous Loss-in-Weight Blenders Chapter 3: Installation 37 Figure 12: Hopper Sizes Hopper Diameter (inches) Approximate Hopper Capacity (@35 lb

Continuous Loss-in-Weight Blenders Chapter 3: Installation 38 Touch “Hopper Setup” Touch the box next to the h

Continuous Loss-in-Weight Blenders Chapter 3: Installation 39 To change a password proceed as follows: Touch the “ACS Group” logo. Enter password

Continuous Loss-in-Weight Blenders iv Table of Contents CHAPTER 1: SAFETY ...6 1-1 H

Continuous Loss-in-Weight Blenders Chapter 3: Installation 40 -Enter original password. -Touch box next to select operator until you see the level

Continuous Loss-in-Weight Blenders Chapter 3: Installation 41 First you must get to the Alarm Setup Page. To do this; Touch the “ACS

Continuous Loss-in-Weight Blenders Chapter 3: Installation 42 All alarm parameters are selectable. If you do not want to use an alarm for a feeder,

Continuous Loss-in-Weight Blenders Chapter 3: Installation 43 Setting Blender for English or Metric Touch the “ACS Group” logo. Enter the password

Continuous Loss-in-Weight Blenders Chapter 3: Installation 44 Touch the box that says “English Units” to toggle between English and Metric ****Note

Continuous Loss-in-Weight Blenders Chapter 3: Installation 45 Enter the Password and touch “OK” Touch “FIFO Diagnostics

Continuous Loss-in-Weight Blenders Chapter 3: Installation 46 The Following screens will appear. This data is provided for trouble shooting blender

Continuous Loss-in-Weight Blenders Chapter 4: Operation 47 Chapter 4: Operation 4-1 Start-up The objective of this chapter is to familiarize the re

Continuous Loss-in-Weight Blenders Chapter 4: Operation 48 The blender will blend at a maximum rate when the lower mass flow weigh hopper has a very

Continuous Loss-in-Weight Blenders Chapter 4: Operation 49 4-2 Controller Description & Operation Display Description The controller on the con

Continuous Loss-in-Weight Blenders v MAINTENANCE...52 Preventative maintenan

Continuous Loss-in-Weight Blenders Chapter 4: Operation 50 “Inventory” page ¾ Clear Inventory ¾ “Next” returns to “Recipe” page “Setup” Page ¾ Tou

Continuous Loss-in-Weight Blenders Chapter 4: Operation 51 Setting a Recipe - To set a recipe, touch the hopper you want to change, a keypad will po

Continuous Loss-in-Weight Blenders Chapter 5: Maintenance 52 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of

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

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 54 Chapter 6: Appendix 6-1 Spare Parts Typical Blender Parts List # DESCRIPTION 015 06

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 55 Annex B Information The following design information is provided for your reference: 1

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 56 6-2 Addendum (Service Supervisor Information) Caution! After all selections are made:

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 57 Once you access the Engineering Menu you will see the following. This is where you

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 58 Feed Factor Filter This filter allows you to set the number of snapshots that the FIFO

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 59 Advance PID Options (mass flow setup) Sample Time once in Steady Window for FIFO Th

Continuous Loss-in-Weight Blenders Chapter 1: Safety 6 Allen-Bradley Controls Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a gui

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 60 PID Integral Constant Works the same as the Gain. Feeder Speed Limits

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 61 Allowed Extruder RPM Change for Steady Flag This is how much the extruder RPM can vary an

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 62 Advanced Alarm Options This alarm is for no material flow through a auger, this could

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 63 6-3 Technical Assistance Parts Department Call toll-free 7 am–5 pm CST 800.423.318

Continuous Loss-in-Weight Blenders Chapter 1: Safety 7 Continuous Loss-in-Weight Blender Safety Tags Tag Description Tag Description Pinch Point

Continuous Loss-in-Weight Blenders Chapter 1: Safety 8 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operatio

Continuous Loss-in-Weight Blenders Chapter 1: Safety 9 1-3 Responsibility These machines are constructed for maximum operator safety when used under