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1. ccc ce eee ee eee eee teens 6 11 Replacing Controller Battery 0 0 ccc cee ees 6 12 Replacing Load CellS 0 0 0 cc ccc cece eee eee eens 6 13 A Appendix We re Here to A A 1 How to Contact Customer Service 0 ccc eee eee A 1 Before YOU balla coee vers ou we ye ne ou we pews Sere oa ye vere dees Genes A 1 Equipment Guarantee 0 0 ccc ce eee eee ees A 2 Performance Warranty gat tot airada idas A 2 Waranty LIMMGUONS sorcorrapavraracrra baratas apa A 2 B Appendix Retrofit Control Blender Start Up Procedures B 1 C Appendix Blow Off Installation Instruction Sheet C 1 D Appendix Calibrating Adjusting Level Sensor pre Sept 2007 D 1 E Appendix Installing Automatic Flow Control Valve Option E 1 F Appendix Installing Dry Air Blanket Option o oooooo o F 1 SECTION Introduction Purpose of the User Guide 1 2 How the Guide Is Organized 1 2 Your Responsibilities as a USer 1 2 ATTENTION Read This So No One Gets Hurt 1 3 Included Safety Features 1 4 How to Use the Lockout Device 1 5 Zero Mechanical State ZMS 1 6 Introduction 1 1 1 2 Introduction ue Purpose of the User Guide This User Guide describes the Conair Trueblend SB 2 Ble
2. 4 Re route and install the wiring from the load cell to the appropriate location in the control box Continued Maintenance 5 15 5 16 Maintenance Load Cell Installation Models TB250 TB500 TB900 continued If the stop bolt 4 and lock nut 5 were loosened during removal or installation they will need to be reset The gap between the upper load cell stop bold and the load cell A should be about 005 use a feeler gauge for value when the weigh bin is in place and at 95 rest Once set tighten the lock nut Screw nut 1 and lock nut 2 onto hanger mounting screw 8 but do not yet tighten The purpose of this bolt and nut is to prevent over travel of the load cell to prevent damage to the cell Use a feeler gauge and make the gap between the load cell stop bracket and the bot tom of the nut 040 Once the distance is set tighten the two nuts Alternatively this can be set by either hanging a weight of 10 kg on each individual load cell hanger brack et or reinstalling the weigh bin and loading it with a total weight of 20 kg Once this weight is installed set the gap between the nut and the load cell stop bracket to zero dis tance then tighten the two nuts To complete the installation of the load cell it is necessary to pre stress the load cells This can be preformed in two ways Either by hanging a weight of 10 kg on each individ ual load cell hanger bracket or reinstalling the weigh bin and placin
3. Bin capacity minor ingredient ft liter Maximum number of materials Number of vertical discharge valves Number of major bin valves Number of minor bin valves Dimensions inches mm Height above mounting plate Width Depth Controller height Controller width Controller depth a ht_lbs ko Shipping Voltage Total amps 115V 1 phase 60 Hz 230V 1 phase 50 Hz Compressed air requirements Discharge valves Maximum loader sizes 20 inch loaders number of loaders 15 inch loaders number of loaders 12 inch loaders number of loaders 8 inch loaders number of loaders TBA TBH100 2 2 11000 400 181 0 6 17 0 3 8 45 25 1149 30 25 769 32 75 832 6 50 165 1 8 75 222 3 160 72 270 122 3 0 1 5 T TOP VIEW TBA H250 500 5 5 2500 950 431 1 6 45 3 1 6 45 3 57 50 1461 36 50 926 40 83 1037 6 50 165 1 8 75 222 3 320 1 440 1 GRAVIMETRIC BATCH BLENDERS TRUEBLEND HIGH HEAT MODELS Model TBA TBH250 TBA TBH900 TOP VIEW TBA H900 BA TBH250 TBA TBH500_ _ TBA TBH900 11 5000 1500 680 2 7 76 4 2 7 76 4 4 4 2 100 60 mm 2 30 mm 63 00 1600 40 13 1026 43 00 1092 6 50 165 1 8 75 222 3 C SIDE VIEW 19 8 9000 3500 1588 4 4 124 6
4. after a short time the green LED lights unit Is set and is In the operating mode Press until the green LED flashes max 5s then release the button Eh Use a small screwdriver or pen and press the adjustment push button until the green LED flashes at one Hz or one flash per second a maximum of 5 seconds 2 Release the button as soon as the flashing starts and after a short time the green LED lights solid This means the unit is set and is in operating mode Unit is set and should need no further adjustment 3 Once the unit is installed hold a finger over the sensing part of the sensor and make sure that the LED changes state from green to red this indicates that the unit is working properly 4 To make sure that the unit is adjusted correctly and not too sensitive close the door and manually run the mixer The LED should not change states while the mixer 1s running which would indicate that the sensor 1s seeing the mixer pass the face ef Tip If this does occur make sure the sensor is inserted flush with the rear plate of the mixing chamber If the unit still sees the mixer while in operation turn the mixer blade to the position where the sensor is sensing the blade and repeat step 1 This will adjust the sensitivity of the sensor so that the blade is invisible but the material will still be sensed during operation Calibrating Adjusting Level Sensor Pre September 2007 This style material sensor used pr
5. eee 1 2 ATTENTION Read this so no one gets hurt 1 3 Included Safety Features 0 0 0 ccc ccc eee ee eee 1 4 MOW t0 Use the LOCKOUT DEVICE dd eho diel tbat hie id 1 5 Zero Mechanical State ZMS 0 0 0 0 ccc eee ees 1 6 2 1 Description What is the TrueBlend SB 2 Blender oooooooomoooo 2 2 PYVDICal AD ONGAUONS 544446554 64544644 565546646554545555454666564 2 2 How it works The TrueBlend 0 0 0 ccc eee eens 2 3 TrueBlend SB 2 System ComponentS 0 00 cee eee eee eee 2 5 Recipe Entry Modes us vuudue sade rate du duvets yeos ture eee deve 2 5 Resin and Product Names 4 424220 6 RS RSE ERERCAEESELE RACED AER S ES 2 5 Specifications TrueBlend 0 cc ce ee eee eee eee 2 6 3 1 Installation Unpacking the BOX8S 0 cc ccc cece eee eee eet e cena naees 3 2 Preparing for Installation 0 0 ce ccc ee ees 3 3 Preparing to Mount the Blender ooooooooommmm 3 4 Ud AAA Pied Pood oed Peele eed hod bead aes 3 5 Mounting the GONUCL ce cneeeecnenee bach baoe sees eanneneebarnene 3 5 Layout of the Material Hoppers 0 0 cece eee ee ees 3 6 Mounting the Loaders 0 0 0 ccc u cece e eee e ene e ewan anes 3 6 Connecting Compressed Air 1 cc eee eee 3 7 Installing the Weigh AU rre SS ste dence edn ety they 3 7 Connecting the Main Power 0 0 ccc cee eee eee eee coro 3 7 Testing the Installation
6. A ana Enter passcode to enable remote protocol Station Identifier software License E FES E FEST 261 65 561 A Close System Network Passcode Continued Operation 4 41 Menus System Setup Network continued Ethernet Communications A variety of software protocols can be used simultaneously on the Ethernet port The devices IP and Subnet mask are set on the Setup Panel Display Advanced screen Modbus 32 bit protocol Modbus TCP IP i Allows the CF Memory card to be accessed from a PC and treated like an external memory card FTP Server Enable the use of an OPC server on a remote PC for remote access read write of the touch screen internal address points VNC Server Service Yes Enable the onboard VNC server This provides connectivity via VNC client running on any PC Allows duplication of touch screen functionality and full control of system from a PC Network Setup System Network Ethernet Serial Communications A variety of protocols are available over the system serial ports Up to a maximum of three ports are available The connected printer uses a USB port and does not take up one of the available serial ports Each port can only be assigned to a single software protocol Serial port functionality is an optional feature Contact a Conair sales or service represen tative for further information Ports available are 4 42 Operation
7. CONAIR www conairgroup com USER GUIDE UGBO20 0313 TrueBlend Blender with SB 2 control Corporate Office 724 584 5500 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your equipment s It s a good idea to record the model and serial number s of your equipment and the date model and serial number s and you received it in the User Guide Our service department uses this information along with the date you received it in the the manual number to provide help for the specific equipment you installed spaces provided p p p quip y Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGBO20 0313 Serial Number s Model Number s DISCLAIMER The Conair Group shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied war ranties of merchantability and fitness for a particular purpose Copyright 2013 The Conair Group All rights reserved Table of Contents 1 1 Introduction Purpose of the User Guide 0 0 0 0 cece eee eee 1 2 How the Guide Is Organized o6c 050b0cconsviededscrarcubucsouens 1 2 Your Responsibilities as a User 0 0
8. TPBX028 091 1 SPECIFICATIONS Side view NOTE Side and front view drawings are model TB900 6 The bin positions change for a TB900 4 see the top view Performance characteristics Batch size lb 9 Maximum throughput rate lb hr kg hr Bin capacity main ingredient ft liter Bin capacity minor ingredient ft liter Maximum number of materials Number of vertical discharge valves Number size of major bin valves Number size of minor bin valves Dimensions inches mm Height above mounting plate Hopper width and depth square Overall depth Control height Control width Control depth Loader center distance Loader center distance Loader center distance Loader center distance Loader center distance Weight lbs kg Installed Shipping Voltage total amps 115V 1 phase 60 hz 230V 1 phase 50 hz Compressed air requirements Discharge valves gt ASCSTIOn mmoouw Maximum loader sizes 20 inch loaders number of loaders 15 inch loaders number of loaders 8 inch loaders number of loaders Front view Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and simple cleanout MODELS TB900 4 TB900 6 19 8 9000 3500 1588 4 4 124 6 4 4 124 6 4 4 2 100 mm 2 60 mm 74 75 1896 48 00 1219 51 00 1296 6 50 165 1 8 75 222 3 6 75 171 5 24 00 609 6 24 00 609 6 NA NA
9. TT TO TMTMmMmMOO WwW Maximum loader sizes 8 inch loaders 12 inch loaders GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB100 4 Top view Mixing chamber access door this side of the interface 10 1 4 sq centered 55 Mounting bolt hole size 4 holes 9 16 in 14 0 mm Predrilled 8 x 8 mounting pattern as standard SPECIFICATION NOTES Maximum throughput rates are based on 35 Ib ft pel letized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper Hopper positions three and four are supplied with eight inch cover plates as standard Numbers in top view drawings represent hopper positions Specifications may change without notice consult with a Conair representative for the most current information Description 2 7 TPBX026 091 1 SPECIFICATIONS Side view NOTE Side and front view drawings are model TB250 4 The bin positions change for a TB250 6 see the top view P
10. Trending Navigate to a trend screen to select from a variety of data values These values are plotted versus time The user can display or manipulate the plots X20 PLC Navigate to screens that display the status of the X20 PLC slices slots and the i o within the system Batch Hopper Navigate to screens that display the status of the current batch being processed by the batch hopper Component Navigate to screens that display the status of the selected gate as well as screens which can perform feed by time and weight tests Simulation Navigate to a set of screens where the various devices in the system can be put into simulation mode Retrieve Resins Retrieve the resins from a USB thumb drive 2 Maintenance E E E Maintenance Continued Operation 4 65 Menus Maintenance continuea Maintenance More Save Retrieve Configuration This feature allows the user to Save the Setup Parameters Save Configuration to a USB thumb drive or to Upload from a USB thumb drive Retrieve Configuration a previously saved file of Setup Parameters If Recipe or Resin names are configured to be part of the Recipe Setup System Recipe this information can be saved or retrieved from a USB thumb drive as well 3 Maintenance Save Configuration Sub Directory MOTE The sub directory is required when the device used is the USB Select Destination Select USB Slot 4 66 Operation
11. 4 4 124 6 4 4 2 100 mm 2 60 mm 74 75 1896 48 00 1219 51 00 1296 6 50 165 1 8 75 222 3 CONTROL SPECIFICATION NOTES Maximum throughput rates are based on 35 Ib ft3 pelletized material and using all of the standard valve sizes Use of valve inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material T The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper gt For loader mounting dimension details refer to the corresponding TrueBlend blender specifications sheet Specifications may change with out notice consult with a Conair representative for the most current information Description 2 15 2 16 TPBX036 091 1 BLENDER ACCESSORIES LEVEL ALARM CONTROL SPECIFICATIONS pl a pa MODELS LAC 1 NEAL 8 0 mm Dimensions inches mm l A Height B Width C Depth Approximate weight Ib kg Installed Shipping
12. Check or None Enables recipient for alarm emails Send to Email Service Address of recipient Enter email addresses of recipients up to three Address Test SMTP Press to test feature Tests email alarm feature by sending test email to enabled recipients Continued Operation 4 39 4 40 Operation Menus System Setup Network Network Setup The Network Setup screen is used to configure any remote communication ports used with the TrueBlend SB 2 system The Ethernet button selects which Ethernet software proto cols are to be enabled Ethernet allows multiple software protocols to be enabled at the same time The serial port button selects which serial port is to be enabled and the desired software protocol for that port A serial port can only have one software protocol assigned to it Network Setup parameters for selecting and configuring the various communication ports and software protocols available Hetwork Continued Menus System Setup Network continuea To enable any remote communications on the TrueBlend SB 2 system a passcode license must be obtained from Conair Contact a Conair sales or service representative to obtain this passcode The first step in setting up remote communications is to select the hardware port to be used Selecting the hardware port displays a screen with specific setup parameters for the hard ware port chosen Network Recipe Setup System Network Main
13. Continued Menus Maintenance continued 3 License station Identifier 24 Software 49 119 Loading License Em Maintenance License Products Menus Manual Control Manual Control Manual Control allows the user or a technician to manually activate each component hop per solenoid valve batch hopper dump valve mixer motor starter mixer dump valve alarm horn and the alarm beacon This screen is useful for diagnosing PLC output problems for each of these blender devices Control EJE Manual Control Operation 4 67 4 68 Operation Menus Trending Trending The maintenance screen buttons allow saving and retrieval of the configuration recipe and resin names to a USB thumb drive This screen also displays the license pass codes for the remote communication option s purchased with the system Trending Navigate to a trend screen to select from a variety of data val ues X20 PLC Navigate to screens that display the status of the X20 PLC slices slots and the i o within the system Batch Hopper Navigate to screens that display the status of the current batch being processed by the batch hopper Component Navigate to screens that display the status of the selected gate as well as screens which can perform feed by time and weight tests Simulation Navigate to a set of screens where the various devices in the system can be put into simulation mode Retrieve Resins Retr
14. adjusted so fines are cleaned away from the sensor but the airflow should not blow material completely away which may cause a false empty situation C 1 Appendix Blow Off Installation Instruction Sheet 1 Mark your location of hole that will need to be drilled and tapped see the illus tration on the next page for your particular blender size 2 Remove the level sensor noting location of adjustment and sensor face mixing chamber front plate mixing chamber mixer and any wiring that is in the way of drilling the hole 3 Drill a pilot hole at indicated location 4 Drill 11 32 hole de burr hole and tap 1 8 NPT Do not run tap fully through the chassis Clean all shavings and fines from the chassis 5 Install item 8 into tapped hole and tighten 6 Slide item 1 into item through the mixing chamber this may be necessary because of welded end Do not tighten yet 7 Install item 7 onto end of item 1 and tighten 8 Remove air inlet to regulator and install item 2 3 4 and 5 and tighten Use thread tape where needed If the compressed air quality is poor and has contami nants in it the fitting should be installed on the outlet side of the regulator The illus tration shows recommended placement of the items but they can be installed as nec essary 9 Route item 6 between item 5 and 7 and insert 10 Re install sensor and wiring 11 Make any adjustments necessary Adjust flow through item 2 so a small amount
15. as well as settable access rights The basic parameters are as follows Parameter Security Beau ina orn Setup Level to Clear Service Guest The security level required to clear the Inventory Operator inventory totals on the Totals page Totals Setup Service Level to Clear Service Operator Guest The security level required to clear the Shift Totals Operator shift totals on the Totals page Setup Service Level to Save Service Setup Guest The security level required to edit and Recipes Operator save the Recipe Resin names in the Resins Setup Service Recipe Book Level to Calibrate Service Operator Guest The security level required to Operator Calibrate the Batch Hopper Setup Service Level for Manual Service Operator Guest The security level required to set or Blender Control Operator test the blender controls in the Manual Setup Service Control Screen Continued Operation 4 49 Menus System Setup Security continued EE Security Level to Clear Inventory Totals Level to Clear Shift Totals Operatorh J Level to Save Recipes Resins Level to Calibrate peratork g Level for Manual Blender Control Operator d Setup Panel Security Basic The advanced parameters are as follows Operator Password Service 3333 be passcode needed to enter the oper ator security level Setup Password Service 2222 The passcode needed to enter
16. 0 0 0 ccc cee eee eee eee naes 3 8 TrueBlend SB 2 Batch Hopper Calibrati0n 3 8 4 1 Operation The TrueBlend SB 2 Operator Control Panel 4 2 Loading Material Into the TrueBlend SB 2 HOppers 4 3 Table of Contents i 4 1 Operation continued Starting the Blending Process 0 cece eee ee eee ees 4 3 Stopping the Blending Process 0 ccc cece eee eee eee 4 3 SEU Se UNO Sc wie ett crasas peros eae ee ss 4 3 e o aden coatactadetaaiae 4 4 MOS csi eee he eee eee eee ee eee oe 4 4 Quick Setup 2 ce cee eee eee eens 4 4 AONO POP OOOO REA A A 4 4 A A O TE eee 4 4 S o o N 4 4 USPrINIBNACO caxarsrarnica A rasrca drid A 4 5 General Concepts 0 0 cece eee eee eee ees 4 5 NAVIGQUON lt 2 cea gnasengsde aan ETETETT ETETETT ETETE TETEN 4 8 Basic Navigation Buttons 0 cece ee eee 4 9 Initial ee 1e OMAR OO C0 55PPO PP 4 10 A E 4 11 Languages A O IA 4 13 RODO PAPAS A e II 4 13 Alarm Log Report zemacaranida dadas cace radicada 4 15 Active Alarm Report v1 02 oo es la a chek ates es 4 16 Current Status Report 0 0 0 ccc eee eee eee 4 16 Shift Inventory Report 0 0 cece eee 4 16 Total Inventory Report 0 0 cece ee ees 4 16 Recipe nsteuseeesteteaeteeeeeeetseeneebaseueeenes 4 16 RESIN RODOM scc 0g2e sous a aa a ads 4 16 Report SEM OIE ccs sack ston eh Ba mee Be ak Boe ee yd ek Bs we nd a Bd 4
17. 17 Logging Report lt lt oscar 4 17 TUCBICNG Repo osease repre 4 18 515181 A APPEAR N 4 19 Security Screen oooooooooo ee eee ees 4 19 AlalMS EEE ETE EE EE ETE EE TET ETENEE TE 4 21 IOWANS coros tops edo EE TETELE ETETETT EEEE led 4 23 SSP cues Hues eeee eee eae oe 4 25 e IA reer eee rere rere rere err ert err re er 4 25 ReCIDO BOOK 22sudicadenecacadddadeaadd adduced gadea dacd 4 30 Loading Opa acon gas ener Gren pees eee nee erario 4 31 I 4 32 System Setup oooooooococo ete eee ees 4 34 ii Table of Contents 4 1 Operation continued APP E O 4 34 Relays Setup cee eee eee eee ees 4 36 AMS SCD es tea 2 ae et te he ee ee EE 4 37 Network gt Doscrrara arar iria 4 40 System Configuration 0 0 cc eee eee 4 43 Panel Setup eee ee eee eee ees 4 45 Cl Pe UE ee ee ee ee ee ee ee ee ee 4 47 Units 1 occ 4 48 O E eee eee ee eee 4 49 Brs1 AOS S57 P U C SEE O O e 4 51 COMPONENT Setup 0 0044 eee cere ees eee a cestos 4 53 Diagnostics dedddudadcnadudaddnedeaedunededddudaas 4 64 Simulation Mode 0 0 cece eee eee eee eens 4 74 DZ A O doin Sod do iniaa deh dn dace 4 74 Checking Emergency Stop Functi0N o lt ooooooooo 4 77 Changing Material in a Blender Component 4 78 Cleaning Mixing Chamber and Hopper 0000 cee eee eee 4 80 5 1 Maintenance Preventative Maintenance Schedule ctesciyescesekyeebrnehveusen gs 5 2 Preventati
18. 182 520 236 6 3 3 2 90 psi 0 2 ft min 6 bars O 0 09 liters sec 1 4 in NPT fitting GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB250 4 AND TB250 6 Top views 4 position 6 position Dimensions shown in inches and mm Mixing chamber access door this side of the interface 16 3 16 sq 411 3 5 32 diameter 80 Mounting bolt hole size 8 holes 9 16 inch 14 0 mm Predrilled 8 x 8 and 12 X 12 mounting pattern as standard SPECIFICATION NOTES Maximum throughput rates are based on 35 lb ft pelletized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material e A 6 position blender recipe of 20 regrind 80 natural 3 color at position 3 2 additive at position 4 3 additive at position 5 and 2 additive at position 6 t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper F TB250 4 hopper positions two and four are supplied with 12 8 adapters with eight inch cover plates as standard TB250 6 hopper position two is supplied with a 12 8 adapter with an eight inch cover Numbers in top view drawings
19. 2 180 The amount of time material will be collected Dump Time Operator 5 2 180 The amount of time it will take to dump the material First Fill Operator 300 0 3600 For the first fill of the receiver body this provides an extended time before generating an alarm Alarm Time Operator 120 The amount of time passed before generating an out of material alarm after the first fill has occurred La 0 3600 Time el Dump Time First Fill Alarm Time Loader Setup Times Menus Blower Setup Blower Setup Control parameters to control the connected pump blower The basic parameters are Blower Address Service 7 0 255 The address of the networked blower not yet supported Idle Mode Enable to use idle mode valve Idle Time Operator 0 9999 Amount of time pump continues to run if no receiver creates a demand 4 62 Operation Continued Menus Blower Setup continued a ee Soup Blower Blower Address Idle Mode ME Y Idle Time Setup Blower Advanced Control parameters to control the connected pump blower The basic parameters are Parameter Security Default MiwMax Descrip Selected Pump Service Primary Primary The name of the blower selected to Secondary edit Primary Pump Starter Service 0 255 The PLC Slot address of the Slot networked blower not yet supported Primary Pump Starter Service Starter Output Channel Number on the Channel Slot Secondar
20. 6 50 165 1 8 75 222 3 6 75 171 5 14 88 377 8 20 00 508 0 9 75 247 7 13 00 330 2 28 00 711 2 400 182 520 236 Mounting bolt hole size 8 holes 9 16 inch 14 0 mm Predrilled 8 x 8 and 12 X 12 mounting pattern as standard SPECIFICATION NOTES Maximum throughput rates are based on 35 lb ft pelletized material using all stan dard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material e A 6 position blender recipe of 20 regrind 80 natural 3 color at position 3 2 additive at position 4 3 additive at position 5 and 2 additive at position 6 t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper TB500 4 hopper positions three and four are supplied with 12 8 adapters with 8 inch cover plates as standard TB500 6 hopper position two is supplied with a 12 8 adapter and an 8 inch cover plate as standard 90 psi 0 2 ft min 6 bars 0 09 liters sec 1 4 in NPT fitting Maximum loader sizes 15 inch loaders number of loaders 8 inch loaders number of loaders NA 2 10 Description Specifications may change without notice consult with a Conair representative for the most current information
21. 6861 You can commission Conair service personnel to provide on site service by contacting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses Before You Call If you do have a problem please complete the following checklist before calling Conair O Make sure you have all model control type from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you J Make sure power is supplied to the equipment J Make sure that all connectors and wires within and between control systems and related compo nents have been installed correctly J Check the troubleshooting guide of this manual for a solution J Thoroughly examine the instruction manual s for associated equipment especially controls Each manual may have its own troubleshooting guide to help you Y Check that the equipment has been operated as described in this manual J Check accompanying schematic drawings for information on special considerations Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Most manuals can be downloaded free of charge from the product section of the Conair website www conairgroup com Troubleshooting 6 15 A 2 Appendix Equipment Guarantee Conair guarantees the machinery and equipment on this
22. Conair representative for the most current information TPBX025 091 1 SPECIFICATIONS Side view Front view lt Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and sim ple cleanout MODELS TB100 4 Performance characteristics Batch size Ib g 2 2 1000 Maximum throughput rate lb hr kg hr 400 181 Bin capacity main ingredient ft liter 0 6 17 Bin capacity minor ingredient ft liter 0 3 8 Maximum number of materials 4 Number of vertical discharge valves 4 Number size of major bin valves 2 60 mm Number size of minor bin valves 2 20 mm Height above mounting plate 45 25 1149 Hopper width and depth square 30 25 769 Overall depth 32 75 832 Control height 6 50 165 1 Control width 8 75 222 3 Control depth 6 19 171 5 Loader center distance 16 25 412 8 Loader center distance 15 50 393 7 Loader center distance 7 75 196 9 J Hopper height differential 6 00 152 4 Installed 160 72 Shipping 270 122 Voltage total amps 115V 1 phase 60 hz 3 0 230V 1 phase 50 hz 15 Discharge valves 90 psi 0 2 ft min 6 bars 0 09 liters sec 1 4 in NPT fitting Number of loaders 2 Number of loaders 2 gt
23. ON during the shift change time in order for the totals to be cleared otherwise the system will not clear them Shift Inventory Report This report shows the current shift totals and the percentage of each ingredient as consumed over the shift Note that 1f the shift totals are not cleared at the beginning of the shift then these values will be added to the prior shift totals Total Inventory Report This report shows the current inventory totals and the percentage of each ingredient con sumed since the last time the inventory totals were cleared Recipe Report This report shows the total amount of material usage consumed since the job has been start ed for each ingredient of the current recipe being run Resin Report This report shows the total amount of material usage for each resin name Requires Resin names to be enabled and resin names to be stored in Recipe Book 4 16 Operation Continued Menus Reports continued Report Schedule Schedule Compact Flash Select the destination where the report should go Destination USB 1 USB 2 Batch Report OFF or ON Select ON to begin logging batch data to the report destination Recipe Report OFF or ON Select ON to begin logging Recipe data to the report destination Save Settings Press Save to save these settings Report Alarm Log Report Formatted Report Compact Flash c Alm Log tx Schedule Report Reports Schedule Automated report generation 1s p
24. Setup This is where the receiver loader parameters are set for each loader body When first entering the loader setup screens the loader 1 is always presented first In the upper left corner of the screen the name of the loader will show this To change to a dif ferent loader the 7 buttons are provided Press these buttons to navigate through the available loaders until the desired loader s name is shown The set parameters shown will now be for the selected loader Control Enable disable and configuration parameters for the receiver body Time Set loading dumping and alarm times for the receiver body Continued Menus Loader Setup ccontinuea Loader Control The following are basic control parameters Control Enable disable and configuration parameters for the receiver body The basic parameters are i a a a Name 0 100 The name of the loader es Enable Service Off On Whether or not this loader is available Loader Type Service 0 15 0 5 1 The capacity of the loader 0 1 8 3 0 Blower Address Service 7 The PLC Slot Address for the Blower Load 1 EE E C ereo 1 Loader Setup Control Loader Times The following page is used to control the loading times and alarm times Time Set loading dumping and alarm times for the receiver body Continued Operation 4 61 Menus Loader Setup ccontinuea The basic parameters are AA A Load Time Operator 10
25. The user can navigate the alarm list using the Up and Down keys The ACK key when pressed acts to acknowledge the alarm Signaling Alarm Message e The alarm beacon flashes e The alarm message is displayed in the top right corner of the screen as a warning triangle e The alarm message is displayed as text when yj is pressed in the navigation bar If a dosing unit does not reach the set weight production does not continue The metering attempt is repeated several times number of attempts can be set If the required value is not reached the alarm beacon is activated Handling Alarm Messages WEE 1 Press a for an overview of all alarm messages 2 Press 4 ACK 3 Alarm Alarm Filter to clear alarms Troubleshooting 6 3 Alarms The ALARM key allows the operator to view silence and acknowledge TrueBlend SB 2 system alarms Possible alarms for the system include Blender Alarms The blender alarm screen displays parameters used to generate alarms for the TrueBlend SB 2 Blender Understanding alarm codes In front of some alarm messages you may see these designators Component 1 Component 2 Etc along with alarm text Component number stands for the component bin that is causing the alarm It is impor tant to look at the alarm text and check to see if there is a problem with the component bin number listed For example the alarm code Component 2 Out Of Material ind
26. Turn power on to the blender Once the controller display comes on and the blender overview screen is displayed continue with the calibration 2 Press the Setup button on the touch screen The TrueBlend SB 2 setup screen will appear 3 Press the Batch Hopper button located at the right side of the screen The next screen to appear will be the Set up screen for the batch hopper 4 Press the Calibrate button 5 Press the Manual Calibrate button It is a good idea to re calibrate the unit after it has been transported and mounted Re calibrating the unit assures that the start weight on the scale inside the blender is zero Tip The weigh bin must be in place and empty when you perform this task If the bin is not in place the calibration will be inaccurate and will need to be redone 6 Press the OK button to obtain the Zero Weight Calibration Factor Please stand by while the system obtains the Zero Weight Calibration Factor 7 Enter the Test Weight Value then press OK 8 Place the test weight into the hopper and press OK to continue with the calibration 9 Stand by while the system obtains the Test Weight AD Value 10 Remove the test weight from the hopper 11 Press the Home button to return to the Home screen Installation 3 9 3 17 Installation SECTION Operation The TrueBlend SB 2 Operator Control Panel 4 2 Loading Material into the TrueBlend SB 2 Hoppers 4 3 Starting the Blendin
27. USB port Farthest away from back of panel S NOTE The printer should be plugged in before the system is turned on in order to properly recognize the printer as attached When the OK button is pressed the report will be generated A pop up screen will appear with a progress bar Once the progress bar pop up vanishes and the report screen is visible the report is complete Should an error occur during the process a pop up will be present ed indicating either a general printer report error or an out of paper error Continued Operation 4 13 Menus Reports continued Reports Print Error Printer generated error Report Cancelled Reports Error 4 14 Operation Continued Menus Reports continued On Demand Select Report Alarm Log Report Select the type of report you Active Alarms Report wish to generate Current Status Report Shift Inventory Report Total Inventory Report Recipe Report Resin Report Report Style Formatted Report Select the style of report you Comma Separated Data File wish to generate Select Destination Select the destination where the report should go Name Alm_Log txt Default report name Press field to edit name El On Demand Select Report Alarm Log Report hod Report Style Formatted Report hod select Destination Mame Alm Log txt Reports On Demand Alarm Log Report This report will output the entire list of historical alarms This list contain
28. Voltages full load amps 9 75 in 110V 1 phase 60Hz 247 6 mm 220V 1 phase 50Hz Line voltage output 110V 1 phase 60Hz 2 110V 2 5 amps 220V 1 phase 50Hz 2 220V 1 3 amps Dry contact voltage outputs 24VDC 8 amps 115VAC 10 amps SPECIFICATION NOTES The line voltage output is determined by the voltage requirements of the LAC 1 Specifications can change without notice Contact a Conair representative for the most current information OPTIONS APPLICATION NOTE i The Level Alarm Control module has seven 7 e Sensor cable length extensions 6 m 20 m capacitance sensor connections Up to six 6 can be used for the monitoring of material levels The sev enth sensor can be used with a surge bin or other e Additional capacitance sensors for use with a surge bin or material storage device located beneath the blender Mi The eighth connection is a dry contact output with 1 JSS TT other material sources N O normally opened and 1 N C normally ar oa 6 closed contact that can be connected to other pro cessing equipment or monitoring devices For exam ple an output used with an alarm connected to a PC monitoring system e Remote alarms compatible with Conair s Universal Alarm Box Capacitance Sensor Connections Remote Alarms Option Satisfactory State When there is no alarm condition this outlet will supply a continuous flow of 110V 220V single phase power Only during an alarm wil
29. a particular device press the device button to go to the single device page Component Mixer Batch Hopper Diagnostics Simulation Main Diagnostic X20 PLC Slices The X20 PLC slices are composed of essentially three pieces a backplane socket an I O module and a 12 position connector The slice or Slot addresses and parts can be seen on the electrical print for the specific model blender All three pieces plug into each other to provide a slice slot Each slice is assigned a slot slice number Slices are then connect ed to each other to form a rack Slice numbers are assigned consecutively from a start point Some backplane modules have Hex encoded rotary dipswitches in them These modules are used as start points to begin the slot numbering scheme Slot slice numbers are Hex dipswitch settings are shown on the electrical enclosure drawing supplied with the system Simulation Navigate to a set of screens where the various devices in the system can be put into simulation mode Continued Menus Diagnostics continuea NOTE It is imperative the slices are placed in the order shown on the electrical drawings and are correctly set the Hex dipswitches This ensures each slice is assigned a correct slice address as defined in the software located within the Master CPU Modules will not function properly if out of order or addressed improperly The entire system is powered by 24vdc The inte
30. and appear to be depressed Note that on some screens it may not be possible to show all navi gation buttons at the same time In these cases the lower right hand side of the screen will show a More button which will scroll through additional navigation buttons An example of the horizontal command bar is as follows Command Bar The buttons present on the command bars will change based on which page is currently being shown Navigation buttons with identical function are located in the same place on numerous pages Note that if the button appears as dark brown then that button will not function indicating the current security level is not high enough or the system operating state prohibits this action Refer to the Operation section entitled Menus Security for more information Continued M enus continued Basic navigation Buttons There are several navigation buttons that are not specific to any page The following sec tion outlines these buttons More This button is used to scroll through the various naviga tion buttons on the screen Either or both the vertical and hori zontal navigation bars may change when this button is pressed Alarm This button is used to change the current screen to the Active Alarms screen This button will also change color to reflect the level of the alarm highest active alarm Refer to the Operation section entitled Menus Alarms for detailed descrip tions and ala
31. are attempted The valve for this low dosed component may be too large Consult the factory for assis tance Troubleshooting 6 7 Loader Option Alarms Alarm Message Motor fault If the there is a problem with the blower motor this alarm will occur Filter fault If the there is a problem with the blower filter this alarm will occur HLx material demand x represents a loader number 1 7 Example HL1 would indi cate a problem with hopper loader 1 The hopper loader has not sent a full message within a specified period Restart If the computer needs to be restarted this alarm will occur 6 8 Troubleshooting Possible Cause Motor protection of the fan motor has tripped Wiring to motor protection is discon nected Differential pressure switch in filter has tripped as the filter became blocked Material may be empty Sensor may be defective Computer needs to refresh or reboot Solution Check motor then switch motor pro tection on again Check connection Switch off conveying and clean the fil ter Check material source Check whether sensor is functioning properly Reboot control or turn main power off for 30 seconds Replacing Fuses This procedure covers the factory installed fuses inside the TrueBlend SB 2 electrical control panel If you have installed an electrical disconnect or emergency stop switch additional fuses and or breakers may have
32. attached and that there is not any material in the bins provided or purchase one from Conair Contact Conair Parts at 2 Reinstall the mixing chamber Follow the instructions on the sticker located inside the ascetics poe BUT OUG the United States call door on the blender chassis to reinstall the mixing chamber 814 437 6861 Mounting the Control 1 Mount the control The HMI operator panel can be mounted on the side of the blender chassis or it can be secured to the blender stand or the processing machine To mount the HMI operator panel on the blender chassis Match the key hole slots on the blender control with the hex head bolts on the side of the blender Tighten the hex head screws and tighten the lock nuts inside the blender chassis The controller with the support can be swiveled by 90 by loosening the rear screw D Note If you decide to remote mount the HMI operator panel you will need to make your own provision to securely mount it The control can be attached to a wall or anoth er position and connected with a 2 m standard or 6 m optional cable The con troller can also be placed on a table and prevented from slipping with the four anti Slip feet which are supplied with the cable 2 Connect the cable Attach the interconnecting DB25 connector cable between the HMI control and the electrical cabinet The cable connects from the back of the box to the fitting underneath the bottom of the electrical cabinet Ti
33. enclosure Improper grounding can result in severe personal injury and erratic machine operation 120 Volt units come with a grounded plug Must be plugged into a grounded out Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non standard operating procedures such as routine maintenance Only qualified personnel should perform troubleshooting pro cedures that require access to the electrical enclosure while power is on N CAUTION Mix blade hazard There are two hazards associated with the mix blades First the blades are driven with substantial torque Never place your hand in the mix chamber unless power is completely disconnected Second the mix blades may become razor sharp Always be careful when touching or cleaning these blades Check for sharp edges frequently Replace blade if a hazard exists N CAUTION Vertical valve hazard Vertical valves in hoppers slam closed without warning They will injure your fin gers Always keep fingers clear of valve openings Never use your fingers to clear an obstruction Never use your fingers to move a sticking valve Introduction 1 3 DN CAUTION Slide gate hazard Never use your fingers to move a sticking slide gate under the mix chamber ZN CAUTION Misuse hazard This blender must be exclusively used for metering and mixing free flowing as per DIN ISO 3435 plastic granulate and additives A total of four to six differen
34. hopper Hopper Empty Setup 0 15lb 0 100 Minimum weight after dump to pre Weight Tolerance vent hopper not dumping alarm Continued Operation 4 55 4 56 Operation Menus Hopper Setup ccontinuea Batch Hopper Control Setup Batch Hopper Control Basic Perform Second Service No Yes No Set to Yes to force the batch hopper to Dump Cycle dump itself out twice per batch completion Unstable Weight Service 1 gram Maximum amount of batch hopper weight Tolerance variation allowed Variation less than this setting will allow dosing to continue Variation greater than this amount will pre vent dosing to continue Max Non Gravimetric Service 10 Maximum amount of time batch hopper Time seconds weight variation can occur before Cannot po Run In Gravimetric alarm occurs Recalculate on first Service No Yes No Set to NO then batch size to dose is recal ingredient only culated after every ingredient is dosed Set to Yes then batch size to dose is recalculat ed only after first ingredient is dosed Batch Hopper Control Service Gravimetric Vol Changes the mode of the blender operation Mode umetric between gravimetric weighed and volumet Gravimetric ric not weighed operation Setup Batch Hopper Control Advanced Continued Menus Hopper Setup continuea Enable high temperature Service No Yes Set to Yes to force the batch hopper to mode No dump itself out then wai
35. lb ft pelletized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 50 natural 40 natural 5 additive material and 5 additive material e A 5 position blender recipe of 50 natural 20 natural 20 natural 5 additive material and 5 additive material e A 6 position blender recipe of 50 natural 20 natural 10 natural 10 natural 5 additive material and 5 additive material t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper Numbers in top view drawings represent hopper posi tions Specifications may change without notice consult with a Conair representative for the most current information TPBX037 091 1 SPECIFICATIONS Model TBA TBH100 SIDE VIEW TOP VIEW TBA H100 MODELS Performance characteristics Batch size lbs 9 Maximum throughput Ibs hr kg hr Bin capacity main ingredient ft liter
36. materials 4 5 6 F Number of major valves 4 6X6 3 6X6 2 6X6 Number of minor valves 0 Dimensions shown in inches and mm 38 965 2 sq 35 889 0 sq 77 35000 12000 5443 77 35000 10500 4763 77 35000 9000 4082 19 482 6 7116 11 2 14 Dimensions inches mm gt Width Depth A TIGOmmoqo0o uy Height above mounting plate Controller height Controller width Controller depth Loader center distance Loader center distance Loader center distance Loader center distance Loader center distance Weight lbs kg Installed Shipping Voltage total amps 240V 3 phase 60 hz 400V 3 phase 50 hz 480V 3 phase 60 hz 575V 3 phase 60 hz sed air requi Maximum loader sizes Number of 25 inch loaders Description 156 3962 72 1828 72 1828 6 50 165 1 8 75 222 3 6 75 171 5 35 75 908 1 35 75 908 1 NA NA 2982 1353 3282 1489 156 3962 72 1828 72 1828 6 50 165 1 8 75 222 3 6 75 171 5 35 75 908 1 35 75 908 1 10 5 266 7 26 13 663 6 3049 1383 3349 1519 156 3962 72 1828 72 1828 6 50 165 1 8 75 222 3 6 75 171 5 35 75 908 1 35 75 908 1 10 5 266 7 26 13 663 6 3115 1413 3415 1549 0 3 ft min 90 psi 6 bars 0 14 liters sec 3 8 in NPT fitting EEES SPECIFICATION NOTES Maximum throughput rates are based on 35
37. of the components must be performed in the field 3 See the electrical drawings supplied with the system for exact connections required Testing the installation You have completed the installation Now it s time to make sure everything works 1 Make sure there is no material in the bender If you have mounted loaders on the blender disconnect the material inlet hose at the source 2 Turn on the main power to the blender Make sure the blender s disconnect dial is in the ON position This powers up the control and the display lights will illuminate T Ta ka k nn 0 00 les fr a Automatic Stop e mai e T System Configuration The TrueBlend SB 2 system is a highly flexible and user configurable system As such it has the ability to store a significant amount of data to completely describe your particular process application and set up This system configuration data only needs to be entered once as it is stored in battery backed memory In addition some of the configuration vari ables have default values which in most cases do not need to be changed A configuration worksheet has been provided in this manual Appendix A that can be filled out so a written log of the system configuration can be saved Section 4 of this manual describes in detail all of the parameters which can be configured See the Operation section entitled Menus System Setup of this manual TrueBlend SB 2 Batch Hopper Calibration 1
38. order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the nor mal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examina tion The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifications provided the equipment is applied installed operated and maintained in the recommended manner as out lined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options e Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation e Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer e Refund the invoiced cost to the customer Credit is subject to prior notice
39. over the drain port Push bin straight in making sure the back of chamber passes under the tab on the back wall of the chassis Some models do not have this tab Install mixing agitator by pushing straight in You may have to rotate the shaft as you install it in order to clear the front bin wall and align the agitator shaft with the keyed drive shaft Align the 1 4 turn fasteners on the front plate with clips on chassis and install front plate Turn the 1 4 turn fasteners clockwise until they tighten Some models require the alignment of the agitator shaft with a bearing installed on the front plate before the plate can be tightened Calibrating Adjusting the Sensor The level sensor switched when material passes in front of the active area The level sensor adjustment depends on the type of material and must be adjusted accordingly Calibrating with no material present LED ring yellow Sensing face Programming buttons Threaded sleeve 1 Make sure the Efector sensor is installed into the rear of the blender chassis so that it is flush with the inside of the rear of the mixing chamber It should be installed as close as possible to being flush and still allow access to push button and indicator light should be facing away from mixing motor towards the outside of the unit 2 Make sure the supplied nut is installed in the back of the sensor tightened against the weld coupling on the back of the chassis 3 Turn
40. plastic strip 1s around the battery so that it can be removed in the future Replace the cover USB There are two USB ports on the back side of the main touch screen unit Remove the access panel door on the back of the control to gain access to the USB ports The USB port that is closest to the touch screen front is labeled USB2 The USB port closest to the back of the PPO45 farthest from the touch screen front is labeled USB1 Either of these USB ports accepts a standard formatted USB thumb drive This is useful for saving a variety of system parameters as well as report generation Files that can be saved are system configuration recipes and resins All reports can be formatted as text files and placed on a USB thumb drive as well A printer with a USB interface can be connected to USB1 This allows for printing of reports directly to the printer This print function only works as a text printer No graphics trends or screen shots can be printed S NOTE The printer should be plugged in before the system is turned on in order for the touch screen to recognize the attached printer Continued M enus continued A standard PS 2 keyboard can be connected to USB2 All 3D buttons in the system are mapped to buttons on the keyboard Mouse entry takes the place of screen touches For data entry the keyboard is fully functional Mouse touch the input field and then use the PS 2 keyboard for the data entry Pressing ENTER will acce
41. represent hopper positions Specifications may change without notice consult with a Conair representative for the most current information TPBX035 091 1 SPECIFICATIONS Side view Front view Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and sim ple cleanout Batch size Ib 9 5 5 2500 Maximum throughput rate lb hr kg hr 850 386 Bin capacity main ingredient ft liter 1 6 45 3 Bin capacity minor ingredient ft liter 0 3 8 Maximum number of materials 4 Number of vertical discharge valves 4 Number size of major bin valves 2 60 mm Number size of minor bin valves removable 2 20 mm Dimensions inches mm Height above mounting plate Hopper width and depth square Overall depth Control height Control width Control depth Loader center distance Loader center distance Loader center distance Loader center distance Loader center distance Weight lbs kg Shipping Voltage total amps 115V 1 phase 60 hz 6 3 230V 1 phase 50 hz 3 2 Discharge valves 90 psi O 0 2 ft min 6 bars 0 09 liters sec 1 4 in NPT fitting 57 75 1467 36 50 926 38 88 988 6 50 165 1 8 75 222 3 6 75 171 5 18 44 468 3 20 13 511 2 15 13 388 2 11 25 285 8 9 00 228 6 Ao EIG0Ommooo Maximum loader sizes 15 inch loaders number of loaders 8 inch loaders number of loaders GRAVIMETRIC BAT
42. store recipes resins or edit recipes resins in the recipe book Select Select the displayed resin or recipe Save Save the current production recipe or the recipe currently shown in the recipe book Recipe Book Navigation to the screens where the stored recipes are viewed and edited Edit Recipe Edit the current recipe in the recipe book Edit Resin Edit the current resin in the recipe book We Save Resin Save the resin in the recipe book El Clear Delete the selected resin or recipe from the recipe book Clear All Delete all of the resins or recipes from the recipe book Material Calibration Navigation to a page where the throughput rate tables for the various extruders can be cleared Continued Menu Recipes continued Recipe Blender EJI LT Recipe Options ill The teed order is automatically set from smallest to largest component Regrind is fed first Material Hatu ralk d y Hatu EYF Material Pati ralk J Recipe Options Continued Operation 4 27 4 28 Operation Menus Recipes continued Recipe Options Recipes Job Status The blender has the capability to store resin names With this feature enabled the user is able to track totals data by resin name instead of just by component number To enable the resin name feature go to Setup System Recipe and set Use Resin Names to Yes The resin names choice wi
43. switching on within two minutes of stop the unit continues the interrupted process This function 1s used to keep downtime in the event of a short power interruption as short as possible The screen that was last open before switching off or power failure is opened If switching on after more than two minutes the internal functions are completely reset The start screen will appear Q NOTE If the metering cycle was interrupted the material in the weigh bin must be removed manually before restarting See step 2 if necessary This will prevent an incor rect mix ratio 2 Remove the weigh bin carefully to prevent damage to the load cell and empty it Only necessary if the metering cycle was interrupted Operation 4 77 Changing Material in a Blender Component Detachable material hopper procedure For models TB 45 4 bins and TB100 2 bin models and TB250R 2 bins All detachable material hoppers are held in place with a captive retainer screw attached to the hopper support frame The retainer stabilizes the detachable hopper when mounted on the blender support frame from forces exerted on the hopper by resin weight and various types of automatic loading receiving devices during normal vibration from the process There is a separate retainer for each detachable hopper To remove any of these detachable hoppers for cleaning or material changeover 1 Remove the automatic loading receiving device 2 Use the proper hex head sock
44. yes no buttons is present to confirm the clearing operation The totals will not be cleared until yes is pressed At that time the current totals will be cleared and the recent totals list will be updated The oldest total will drop off the list For clearing recipe and resin totals a confirmation popup will appear Pressing yes will clear the totals There is no history for these totals With these totals it is possible to clear an individual recipe resin entry total or the entire table The total shown on the page will be the individual total that is cleared Continued Operation 4 23 4 24 Operation M enus Tota S continued Inventory Clear the inventory totals Shift Clear the shift totals Recipe Totals Navigate to the totals page to display inventory totals for recipes Resin Totals Navigate to the totals page to display inventory totals for resins ara Blender i E Batches E Totals 1 PA Ja y Totals Clear Shift Inventory Continued Men us Totals continued Monitor Home Screen A Home screen provides a detailed view of the system status This monitor information is shown on the Home screen The displayed data includes the current operating state Automatic or Stop the recipe name and number the current recipe set points shown in blue the current recipe actual values shown in black each components material type Natural
45. 6 1 1 d feeder 2 Select the proper dosing rates for the different valve configurations from the fol lowing table Example Blender XYZ Component 1 3 X 6 valve 4000 g s Component 2 3 X 6 valve 4000 g s Component 3 2 X 3 valve 850 g s Component 4 2 X 3 valve 850 g s Component 5 2 1 d feeder 40 g s Component 6 1 1 d feeder 8 g s 3 Enter the default flow rates into the blender control on the dosing rate screen 4 Select the proper default settling times for the different valve configurations from the following table Example Blender XYZ Component 1 3 X 6 valve 1 5 s Component 2 3 X 6 valve 1 5 s Component 3 2 X 3 valve 1 5s Component 4 2 X 3 valve 1 5 s Component 5 2 i d feeder 5 s Component 6 1 1 d feeder 10 s 5 Enter the default settling times into the blender control on the settling times screen 6 Runa material calibration for each of the components 7 Run the blender making sure that all materials are present in sufficient quanti ties for correct operation While running the blender control will automatically adjust the dosing rate for optimum operation Appendix B 1 The blow off kit is available from Conair Part 61126101 Contact Conair Parts 1 800 458 1960 From outside of the United States call 814 437 6861 lt S NOTE The air should be
46. Batch hopper should rest before a feed weight is read Continued Menus Component Setup continued Component 1 Control Mame Component 1 Minimum Gate Time m Settling Time mE so Setup Component Control Basic The advanced parameters are as follows nom IDO bd anes cr AI Large Table Resolution Service 20 0 999 The time difference in milliseconds between entries in the feed table for large feed rates Small Table Resolution Service 10 0 999 The time difference in milliseconds between entries in the feed table for small feed rates Dosing Rate Service 300 0 999 The default dosing rate in grams second used for volumetric mode Minimum Feed Weight Service 25g 0 999 The minimum amount of feed required before an out of material alarm occurs Maximum feed error Security 50 0 999 The maximum dosing eror allowed before Percentage the material calibration table is cleared Control areren T eeo corer EE Setup Component Control Advanced Operation 4 53 Menus Alarm Setup Alarms The component alarm screens display parameters used to generate alarms for the compo nent feeders Alarm sets parameters which control when a component alarm might occur The basic alarm parameters are Out of Specification 0 100 Percent to exceed before alarm Clear Gate Calibration after Setup No Yes No Yes forces the material feed table Out of Spec to clear Quantity of incor
47. CH BLENDERS TRUEBLEND TB250R 4 Top viewS 4 position MOUNTING INTERFACE Dimensions shown in inches and mm Mixing chamber access door this side of the interface 3 5 32 diameter 80 Mounting bolt hole size 8 holes 9 16 inch 14 0 mm Predrilled 8 x 8 and 12 X 12 mounting pattern as standard SPECIFICATION NOTES Maximum throughput rates are based on 35 lb ft pelletized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper TB250R 4 hopper position two is supplied with a 12 8 adapter with an eight inch cover plate as standard Position three and four are supplied with hand fill lids Numbers in top view drawings represent hopper positions Specifications may change without notice consult with a Conair representa tive for the most current information Description 2 9 TPBX027 1011 GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB500 4 AND TB500 6 SPECIFICATIONS Side view Front view Top view Drain chute Purchase the optional material drain chute that readily installs to the chassis ope
48. Check the operating pressure with the manometer C and if it is different set it to 0 6 MPa u0 18 815Uu Installing the Weigh Bin 1 Visually inspect the pins on the weigh bin and the interfacing parts located on the load cell inside the blender chassis 2 Guide the pins or hangers depending on blender model onto the interfac ing part inside the blender Connecting the Main Power The blender operates from standard 120 Volt 60 Hz or 220 Volt 50 Hz depending on the option selected when purchased You can confirm power requirements by looking at the serial tag 1 Plug the blender into a properly sized electrical outlet IMPORTANT Always refer to the wiring diagrams that came with your blender to locate specific electrical amp S NOTE Blenders ordered with 220 Volt will need to be wired to a discon nect that is protected by properly sized protectors fuses or breaker AN components Illustrations in CAUTION Always disconnect and lock out the main power sources rear Ende before making electrical connections Electrical connections should be to be representative only made only by qualified personnel Installation 3 7 3 8 Installation Preparing for Electrical Installation 1 The operator touch screen for the TrueBlend SB 2 system should be conveniently located for easy operator status 2 Each component has been prewired at the factory so only the wiring required to interconnect all
49. Feed by Weight Results Continued Menus Diagnostics continuea The Diagnostic Component Time screen allows the user to specify an exact Time for a material to dose as a test of the valve and weigh system This is useful if a particular resin 1s required to dose a very low percentage or is of an unusual geometry or size The user can use this screen to determine the overall capability of a component valve and a material to dose The user can select the Number of dose tests and the test Time to dose Press OK to begin the dose test after setting the prior fields Press the Time Results screen to observe each timed dose test 37 omponert 1 Diagnostic Time 0 0000 g 0 0000 q Dosing Rate qs e i TAE EA Diagnostic Feed by Time Results Continued Operation 4 73 4 74 Operation Menus Diagnostics continuea Simulation Simulation mode makes it is possible to put the devices that comprise the system into a simulation state This is useful for training purposes if the user would like to simulate the operation of the blender without running material though the blender Simulation Navigate to a set of screens where the various devices in the system can be put into simulation mode From the main simulation page the entire system may be put into and out of simulation To change just an individual device place it in simulation from the device individual page To adjust the simulation characteristics of
50. Mame EEE a JE uo sl teo e Setup Component Control Advanced Component Setup The component setup screens are used to set parameters that are relevant to an individual material hopper Parameters include Control and Alarm parameters A blender will have multiple material hoppers and each hopper will have its own parameters When first entering the component setup screens the component is always presented first In the upper left corner of the screen the name of the component will show this To change to a different component the buttons are provided Press these buttons to navigate through the available components until the desired component s name is shown The set parameters shown will now be for the selected component Control Setup Control parameters that are used to control the algorithm for monitoring the weight in the hoppers and setting the extruder speed Control This screen sets control parameters which affects the perform ance of the control algorithm Alarm This screen sets parameters which control when a component alarm might occur The basic parameters are Name Service Component Name of the component used in 1 reporting Minimum Gate time Setup Hopper 0 9999 The minimum amount of time the ms Size gate can open and feed material reli Dependent ably In milliseconds Setting Time ms Service 800 0 9999 The amount of time the material fed into the
51. Menus System Setup Configuration To configure a serial port first select the port you wish to configure Then the setup values for the selected port will appear and can be adjusted erator CL Dassen Serial Port Serial Port 1 Port 1 2 or 3 The serial port to configure Protocol Service None Modbus Allen The protocol to use on the serial port Bradley DF1 Baud Rate Service 19200 4800 9600 The data rate used on the port 36400 57600 115k Parity Service Even None Even The type of parity on the port Odd High Low Bits per Service 7 8 The number of bits in the data byte Character EJEA Network Baud Fate 4 92004 d Setup System Network Serial System Configuration This screen sets parameters that dictate what and how the overall system is being con trolled Any changes on this screen will greatly change the operation and screen appear ance of the system To change any of the values on this screen the security level must be at the Service level and the system must be stopped After any changes made on this screen a system restart will be required This is to insure that all the appropriate hardware processes and software parameters are properly set After making changes to the application or control modes of the devices the operator will be asked to enter a new recipe entry method A recipe is the method for the user to enter the target throughput data into the system Each type of application
52. NA 550 249 700 318 6 3 3 2 19 8 9000 2800 1270 4 4 124 6 2 2 62 3 6 6 2 100 mm 4 60 mm 74 75 1896 48 00 1219 51 00 1296 6 50 165 1 8 75 222 3 6 75 171 5 24 00 609 6 18 00 457 2 11 19 284 2 15 00 381 0 33 44 849 3 550 249 700 318 6 3 3 2 90 psi 0 2 ft min 6 bars 0 09 liters sec 1 4 in NPT fitting UY GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB900 4 AND TB900 6 Top views 4 position 6 position MOUNTING INTERFACE Dimensions Mixing chamber access door this side of the interface shown in inches 19 7 8 505 sq and mm 16 406 sq 8 203 sq 3 15 16 diameter 100 Mounting bolt hole size 8 holes 9 16 inch 14 0 mm Predrilled 8 x 8 and 16 X 16 mounting pattern as standard SPECIFICATION NOTES Maximum throughput rates are based on 35 lb ft pelletized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material e A 6 position blender recipe of 20 regrind 80 natural 3 color at position 3 2 additive at position 4 3 additive at position 5 and 2 additive at position 6 t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the option al flow control valve when moun
53. O Inspect hoses for damage or wear Damaged compressed air hose can allow moisture or contamination to seep into the system Replace any hose that is torn or cracked O Inspect the installation Check installed mounting hardware to make sure that the installation 1s secure O Inspect the compressed air system Check the compressed air system for leaks Compressed air leaks could compromise the performance of the TrueBlend SB 2 system O Drain the water separator in the compressed air system e Yearly or as often as needed O Replace the TrueBlend SB 2 controller battery See Troubleshooting Replacing Controller Battery O Calibrate adjust load cells on TrueBlend SB 2 hopper s 5 2 Maintenance Loading Equipment The TrueBlend SB 2 component hoppers are generally loaded with a vacuum receiver The proper operation of the loading receiver component is necessary for accurate control of the TrueBlend SB 2 component hopper Software Upgrades Upgrading software on the TrueBlend SB 2 controller is accomplished by downloading the latest software version from Conair burning the software onto a compact flash card and installing the compact flash card into the TrueBlend SB 2 touch screen controller Alternatively a pre programmed Compact flash card can be ordered from the Conair serv ice department To download the most up to date TrueBlend SB 2 software version contact Conair service Once the software is downloaded it is burne
54. Regrind Additive Natural or Additive Batch the current batch hopper weight in lbs kg and the estimated usage rate in lbs hr kg hr To indicate the Open status of each component valve the batch hopper dump valve or the mixer dump valve the A symbol is displayed aaa To indicate the On status of mixer agitator the symbol Q is displayed To indicate the Covered status of the mixer proximity switch the symbol 1s displayed Home Blender Menus Recipes Recipe The recipe screen is provided to enter the target set values or Recipe for the system s auto matic operational state These pages are highly dynamic and depend upon the configura tion chosen during Setup All variations will not be shown here Whenever the user edits the New recipe values a temporary recipe is being edited It is not being used to control the system The system will control the blender according to the New recipe values only after the Automatic button is pressed This copies the recipe from the New Recipe to the Current Recipe When Automatic is pressed the New Recipe is checked for problems If there are no problems with the Recipe the recipe will be copied to the Current Recipe and the system will control the blender accordingly If there is a problem with the recipe an orange recipe Error button will appear on the screen Pressing this Error button w
55. ailable from Conair e Tip You may also want to clean the material receiver at this time while accessing the grav ity dump valve through the respective blender clean out door Contact Conair Parts 1 800 458 1960 From outside of the United States call 814 437 6861 7 Reassemble blender If using the optional drain chute be sure to engage the safety switch into the compartment receptacle Operation 4 79 Cleaning the Mixer CAUTION Mix blade hazard There are two hazards associated with the mix blades First the blades are driven with substantial torque Never place your hand in the mix chamber unless power is completely disconnected and appropriate lock out tag out procedures have been followed Second the mix blades may become razor sharp Always be careful when touching or cleaning these blades Check for sharp edges frequently Replace blade if a hazard exists 1 Open the quick release locks of the mixing chamber end cover and remove it 2 Once the material compartment has been cleaned remove the deflector This will enable you to clean the mixing chamber and the shut off valve at the bottom of the chamber You may need to run the mixing agitator for a short time to fully evacuate the mixing chamber If not necessary skip to step 6 3 Close the mix chamber access door 4 Restore power by closing the main disconnect switch 5 Manually run the mixer for a short time to lower the material level Refer to the Opera
56. alve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 50 natural 40 natural 5 additive material and 5 additive material e A 5 position blender recipe of 50 natural 20 natural 20 natural 5 additive material and 5 additive material e A 6 position blender recipe of 50 natural 20 natural 10 natural 10 natural 5 additive material and 5 additive material t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper Numbers in top view drawings represent hopper posi tions Specifications may change without notice consult with a Conair representative for the most current information Description TPBX033 091 1 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB3500 4 TB3500 5 AND TB3500 6 Front view Side view front front NOTE Side and front view drawings are shown for model TB3500 6 The bin positions change for a TB3500 4 and TB3500 5 models see the top view front MODELS TB3500 4 TB3500 5 TB3500 6 Performance characteristics Batch size lbs g Maximum throughput lbs hr kg hr Bin capacity main ingredient ft liter 18 510 18 510 18 510 Bin capacity minor ingredient ft liter 18 510 9 255 9 255 Maximum number of
57. ance 35 75 908 1 Loader center distance NA Loader center distance NA Loader center distance NA Weight lbs kg Shipping Voltage total amps 240V 3 phase 60 hz 400V 3 phase 50 hz 480V 3 phase 60 hz 575V 3 phase 60 hz Compressed air requirements 55 25000 9000 4082 111 5 2832 1 72 1828 0 72 1828 0 6 50 165 1 8 75 222 3 6 75 171 5 gt ASCSTIOn mmoouw 2483 1126 2783 1262 55 25000 8000 3629 10 283 5 142 5 3 6X6 2 2X6 111 5 2832 1 72 1828 0 72 1828 0 6 50 165 1 8 75 222 3 6 75 171 5 35 75 908 1 35 75 908 1 10 5 266 7 26 13 663 6 20 0 508 0 2531 1148 2831 1080 GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB2500 4 TB2500 5 AND TB2500 6 55 25000 7000 3175 10 283 5 142 6 2 6X6 4 2X6 111 5 2832 1 72 1828 0 72 1828 0 6 50 165 1 8 75 222 3 6 75 171 5 35 75 908 1 35 75 908 1 10 5 266 7 26 13 663 6 20 0 508 0 2580 1170 2880 1306 0 3 ft min 90 psi 6 bars 0 14 liters sec Maximum loader sizes 3 8 in NPT fitting front Dimensions shown in inches and mm 38 965 2 sq 35 889 0 sq UNTING INTERFACE DW gt al a Ko o ie nN S E o Nm 3 m Co m SPECIFICATION NOTES Maximum throughput rates are based on 35 Ib ft pelletized material using all standard v
58. and with a surge bin attached A frame with reservoir hopper and exhaust box is available if it is used as a centralized mixing sta tion The frame can be bolted to the floor e Make sure that the base is as even as possible e Make sure that the switch cabinet and main door are accessible for maintenance work at all times e Match the bolt pattern on the bottom of the blender with the mounting surface And optional adapter 1s available It may have been ordered pre drilled or 1t may be blank so that it could be custom drilled by you Mounting interface dimensions are available in this manual on the specification sheets Match the through hole size on the mounting plate with the appropriate bolt size You are responsible for the structural integrity of your installation Make sure to use the largest bolt that will fit properly into the through hole Use the hardware supplied to bolt the blender to the stand The bolts you should use are attached to the stand Mounting the Blender amp S NOTE If your mounting surface does not match the standard bolt 1 Lift the blender into position Using the lifting lug located at the center of the blender patterns available you will need lift the blender only into position This lifting lug was designed to lift the weight of the an adapter You can make an blender only Make sure that the blender has the mixing chamber and control removed adapter using the dimensions that no loaders receivers are
59. ates less scrap The TrueBlend SB 2 blender automatically adjusts for variations in material type density and geometry Typical Applications 1 Unit mounted directly on the processing machine 2 Unit operated as a centralized mixing station If used as a centralized mixing station a frame with reservoir hopper and exhaust box is available The frame can be bolted to the floor How It Works Understanding the Parts of the TrueBlend SB 2 Cover for Vertical Valve Assembly Supply Hopper Weigh Bin Pneumatic Cylinder Load Cell Mixing Chamber Mixing Agitator Mixed Batch Ta AJI mi Material Vertical Dispense Valve Weighed Batch Level Sensor Slide Gate Manual or Pneumatic D Note Pneumatic slide gate is supplied when a blender is remote mounted i e on surge bin floor stand etc and replaces the manual slide gate The pneumatic discharge slide gate is not installed if a manual slide gate is installed and the unit is mounted directly on the injection molding machine Description 2 3 How It Works The TrueBlend The TrueBlend SB 2 meters and mixes free flowing plastic granulate regrind and natural material and additives The unit mixes four to six materials depending on model and con figuration The unit meters each ingredient into a gain in weight material batch hoppers with mounting flanges for one hopper loader each All components are dispensed by pneu matic vert
60. been used elsewhere in the main power cir cuit Located inside the TrueBlend SB 2 electrical control panel are fuses for the AC line FUI and the power supply output side FU2 and FU3 To replace a blown fuse 1 Disconnect and lockout the main power 2 Open the electrical enclosure door Turn the screws on the front panel counter clockwise to open 3 Replace the fuse The fuses are located inside the control cabinet and are labeled and identified on the subpanel and the electrical print 4 Close the electrical enclosure and restart the unit Troubleshooting 6 9 Replacing Controller Battery The TrueBlend SB 2 touch screen controller uses battery backed memory to store a vari ety of configuration control and status data If the battery drains to a low voltage a sys tem alarm will occur to inform the user If the battery is drained and power to the sys tem is removed the data stored in battery backed memory will be lost To avoid this once the alarm is occurring replace the battery with system power applied The battery is Conair Part Number 2671080303 This battery is replaced by removing the battery cover and pulling on the plastic tab to extract Take care when inserting the battery that the plastic strip is around the battery so that it can be removed in the future The controller battery is available from conar 1 Disconnect the power supply to the Power Panel Touch the housing or ground connection not the power s
61. ble by the user If the current security level is not high enough to perform a certain function then the input box or button will be dark brown in color Touching the input box or button while it is locked will change the screen to show a popup indicating an invalid action The user must either enter a passcode or close the popup and return to the present screen S NOTE In some cases the system operating state will lock the input box or button In this case a different popup will appear informing the user that the system must be Stopped before perform ing the desired action Upon closing this popup the user will be returned to the present screen view On each screen page in the upper left corner a numeric box indicates the current level of security The security level is indicated by a number as well as color code The security number level color and default passcodes are as follows 0 Green Guest minimum security level e 1 Yellow Operator Passcode 3333 2 Orange Setup Passcode 2222 3 Red Service maximum security level Passcode 1111 The passcodes for each level can be changed in the Setup Panel Security screen Refer to the Operation section entitled Menus System Setup Security for more information regarding user defined passcodes and setting up the security system Also available with the security system is an Auto Logout feature I
62. by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating con dition including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied aris ing by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose Retrofit Control Blender Start Up Procedures When the TrueBlend Controller is used in retrofit replacement applications follow the initial setup procedure below to ensure your blender will run at its optimum accuracy This procedure sets the default dosing rates and settling times This set up will help the blender control home in on the actual dosing rate quicker 1 Determine the valve configuration for the particular blender This can be done simply by measuring the operating mechanisms and noting the type of mechanism Example Blender XYZ Component 1 3 x6 valve Component 2 3 x6 valve Component 3 2 x3 valve Component 4 2 x3 valve Component 5 2 1 d feeder Component
63. ceiver is currently loading The receiver is currently dumping The receiver has not filled within the specified time limit and is generating an alarm Loading Status Operation 4 31 4 32 Operation Menus System Setup CONAI 675 005 01 Setup Setup is used to configure the TrueBlend SB 2 systems operating parameters the calibra tion the blender model number number of component bins batch hopper weight and other parameters It also contains the configuration menus for remote communication protocols and all TrueBlend SB 2 Maintenance and Diagnostic functions Each Setup parameter is configured and then stored in permanent memory All setup parameters can be viewed by the user however the current security level and operating state will dictate whether or not the parameters can be adjusted If while in setup a parameter needs to be changed touch the desired input field If the system operating state does not allow a parameter field to be edited a security violation warning screen will appear A passcode entry field will be presented If the correct passcode is entered the field will become editable S NOTE After changing any setup parameter DO NOT power down without first returning to the HOME screen and waiting for at least a minute The system requires this time to store any parameter changes to the Compact Flash CF card installed in the touch screen To navigate the Setup screen fir
64. ch hopper The raw AD Output value is a 7 digit number This number is typically in to 2 3 million range with the batch hopper empty It is in the4 6 million range when the batch hopper is full of material At no time should this value be above 8 million if itis the loadcell is most like ly defective or damaged The Minimum and Maximum gram variance fileds indicate the total vibration range seen by the batch weigh hopper Batch Statistics displays the present batch accuracy and feed characteristics Here the set actual weights of each component are listed as well as their feed tolerances The num ber of feeds for each component as well as the feed times are also listed Pressing the SAVE button on this screen allows the user to output the last 50 Batch Statistics to a USB thumb drive to later view on a PC using Excel Dosing rate indicates the current grams second dosing rate capability of the individual com ponents with material Continued Menus Diagnostics continuea ja Batch Hopper Diagnostic Stable Weight Yes Diagnostic Batch Hopper Diagnostic Component This page provides information regarding the feed of a component itself The column indicates dose number that occurred to dose the required component SET gram amount The Time indicates the number of milliseconds the gate was opened the Weight column indicates the amount of grams dosed for the given Time The Average indicates the average gram amount dosed fo
65. ction built into the system Powering the system on for the first 1 G09 ae eee time with new software requires a software licensing code to be entered in order to contin il he i EEEE ue the boot process For new installations this will have been completed by Conair before 814 437 6861 shipment Contact Conair technical support 1f the system does not boot Initial Page SOT are license does not match station identifier Please enter a new software licenze Software Licenze ES E EN gt E gt Initial Page License Entry 4 10 Operation Menus Home Home The buttons present on the command bars will change based on the page being displayed Navigation buttons with identical function are located in the same place or will vary based on the application control modes and recipe entry method selected For this reason not all representations of this screen will be shown here but the functionality of all these screen variations will be discussed Across the bottom of the screen is a typical command bar The most common functions needed to run and monitor the line will be on this command bar The lower right of the screen shows two buttons Automatic and Stop These buttons will control the state of the blender On these buttons is an indicator showing the current operating state The possible data shown on the screen includes the current system throughput the current job name and the name of the current production reci
66. d of ca 0 g at zero calibration is an indication that the load cell should be replaced Screws holding the weigh bin mount to the load cell HA CS me Weigh bin mount key hole slot on weigh bin Maintenance 5 11 5 12 Maintenance Weigh Bin Mount Installation and Adjustment Models TB045 amp TB100 continued 7 Once the pieces are adjusted correctly install the weigh bin mount onto the load cell Place removable strength Loc tite on the two screws and lightly tighten Once the mount is in place adjust the bracket until it is perpendicular to the load cell This can be accomplished by looking through the key hole slot in the weigh bin mount and comparing the edge of the load cell to the upper edge of the key hole slot they should be parallel 8 After the items are placed correctly fully tighten the two screws and torque to 10Nm 88 in Ibs Replace the weigh bin and calibrate re zero the load cell as described in the Operation section entitled Menus Hopper Setup Load cell edge Weigh Bin Installation and Adjustment Models TB250 TB500 TB900 The weigh bin needs to set freely in the bottom of the slots and the hoses are to be connect ed in the quick disconnects S NOTE Weigh bin mount adjustment is not necessary or recommended for the TB250 and larger models Maintenance 5 13 Load Cell Removal Models TB250 TB500 TB900 WARNING Electric Shock High voltages can cause life thr
67. d onto the compact flash card using the flash card burner available from the Conair Parts Department Spare flash cards are also avail able Once the flash card is burned with the software install it into the TrueBlend SB 2 touch screen Turn the orange compact flash safety latch away from the compact flash 1 Then press the compact flash ejection lever with a screwdriver 2 until the compact flash is ejected The compact flash card can now be removed by hand 3 Install in reverse order To order a pre programmed Compact flash card Contact Conair Parts 1 800 458 1960 From outside of the United States Call 814 437 6861 gt D gl v O CD Maintenance 5 3 5 4 Maintenance Checking Emergency Stop Function See the Operation section entitled Checking Emergency Stop Function Changing Material in a Blender Component See the Operation section entitled Changing Material in a Blender Component Cleaning Mixing Chamber and Hopper See the Operation section entitled Cleaning Mixing Chamber and Hopper Testing the Safety Interlock Function Test the safety interlock function by opening the mixer chamber door The alarm should sound and the blender should stop Check the component hopper safety interlocks if appli cable by opening each compartment door The alarm should sound and the blender should Stop Draining the Water Separator 1 Loosen the knurled screw 2 on the bottom of
68. dditive material and 5 additive material e A 5 position blender recipe of 50 natural 20 natural 20 natural 5 additive material and 5 additive material e A 6 position blender recipe of 50 natural 20 natural 10 natural 10 natural 5 additive material and 5 additive material t The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper Numbers in top view drawings represent hopper posi tions Specifications may change without notice consult with a Conair representative for the most current information TPBX032 091 1 SPECIFICATIONS Side view Front view NOTE Side and front view drawings are shown for model TB2500 6 The bin positions change for a TB2500 4 and TB2500 5 models see the top view Performance characteristics Batch size lbs g grams or kilograms Maximum throughput Ibs hr kg hr Bin capacity main ingredient ft liter 10 283 Bin capacity minor ingredient ft liter 10 283 Maximum number of materials 4 Number of major valves 4 6X6 Number of minor valves 0 Dimensions inches mm Height above mounting plate Hopper width and depth square Overall depth Controller height Controller width Controller depth Loader center distance 35 75 908 1 Loader center dist
69. displays the recipe resin system and device inventories To access the totals screen from the Home screen press the Totals button Two types of material con sumption totals are accumulated in the system The first is the running total labeled Total Inventory The second is called Shift Totals This allows users to track material usage during a shift Separate buttons are provided for clearing the two total types Like other screens in the system the totals screens can vary based on the system configura tion If resin names have been enabled then a button on the command bar will change the page to allow named resin totals to be viewed For resin and recipe totals the page displays the recipe resin name number and total An individual recipe resin total can be viewed by directly keying in the number of the recipe resin in the table or by pressing the Up Down buttons to scroll through the table of resin names until the desired resin total is reached Holding down these buttons will scroll the available values Single presses will increment decrement the resin number by 1 Also displayed on the totals pages are buttons to Clear the totals Clearing totals requires a higher security level Separate Clear buttons are provided for clearing inventory or shift totals When one of these buttons is pressed the screen displays the time and value of the last five totals that were cleared A confirmation box with
70. e slice numbering system to account for future expansion of the system For each slice the main page indicates the following e Slice status to indicate if the slice at the specified location is operating correctly OK If the slice is Bad Missing the slice is not installed the slice contains a major fault or the slice type is not valid for the specified location That is the slice is OK and communicating but the ID returned does not match the slice type defined for that slot location The B amp R part number The B amp R serial number of the slice The version of the firmware installed in the slice The hardware version of the slice For each slice there is an Advanced page This page displays the operational data of the slice The data includes the status of the digital and analog inputs outputs and any status information Some fields in the advanced pages allow user entry if the correct security level is entered Private This is only for development purposes and therefore the password to access this level is not published 4 s20 PLE Diagnostics Shutting Off in Emergency 1 Switch the main switch to off The power supply is interrupted If the cone valve was open it is closed All other machine movement is stopped immediately The batch is not finished The main switch can also be locked manually with a lock Restarting after Emergency Stop 1 Switch the main switch to on If
71. eatening currents in the body and injury from elec tric shock Allow only trained and qualified electrical technicians to work on the electrical system Before any electrical work disconnect the unit from the power supply and lock to prevent unauthorized persons switching it on Do NOT use excessive force Forces that are exerted on the load cell from outside when attaching and removing the weigh bin load cell may damage the very sensi tive load cell 1 Remove the weigh bin 2 Disconnect the wiring that extends into the control box see wiring diagram 3 Look at the general location of all items to see how the items are installed before removing 4 Remove the load cell cover plate 7 by loosening the load cell cover plate holding nuts 4 and sliding the cover upward off of the studs 5 Unscrew the two hex nuts 2 and 3 and remove the two hex bolts 5 from the load cell 6 Remove the weigh bin hanger 6 7 Remove the two screws that mount the load cell to the load cell mounting bracket 11 and remove the old cell e Tip There is no need to remove the stop screw 9 and lock nut 10 during removal of the load cell It should remain in place so no adjustment is needed after installation 5 14 Maintenance Load Cell Installation Models TB250 TB500 TB900 WARNING Electric Shock High voltages can cause life threatening currents in the body and injury from elec tric shock Allow only trained and qualifi
72. ed Panel screen Saver Time Setup Panel Display Basic After the screen for the Advanced parameters is closed the system will be updated with the new values To change the IP address Subnet mask or Gateway edit the values and press SET A system restart 1s not required after changing these values The advanced parameters are as follows A Dama ossopnon Ey Pane IP Address SUbMet Maszk ME al e iy a y Setup Panel Display Advanced Operation 4 47 4 48 Operation Menus System Setup Units Units This screen parameters relevant to the units the system uses for display and data entry Units Setup the numerical units used by the system The basic parameters are as follows Units Setup English Use the English system of units for data entry and display Can be changed to Metric EN units Setup Panel Units Basic The Display Precision parameters allow the user to define the number of decimal places to display S NOTE Only weight parameter is used for blending operations Continued Menus System Setup UnitS continuea Units Display Precision Weight Time Length Time p Weight Area Log weight Logs I Time Log eight Setup Panel Units Display Precision Menus System Setup Security Security This screen sets parameters relevant to the security system Security Setup the pass codes for the various security levels
73. ed air requirements 40 18000 6000 2722 94 4 2397 8 53 0 1346 2 53 0 1346 2 6 50 165 1 8 75 222 3 6 75 171 5 lx IoOonmouooaw gt Front view B gt 40 18000 5500 2495 6 170 4 113 5 3 5X5 94 4 2397 8 53 0 1346 2 53 0 1346 2 6 50 165 1 8 75 222 3 6 75 171 5 30 00 762 0 30 00 762 0 4 25 108 0 21 63 549 3 1498 6 1748 7 GRAVIMETRIC BATCH BLENDERS TRUEBLEND 1B1800 4 TB1800 5 AND TB1800 6 40 18000 4800 2177 6 170 4 113 6 2 5X5 94 4 2397 8 53 0 1346 2 53 0 1346 2 6 50 165 1 8 75 222 3 6 75 171 5 30 00 762 0 30 00 762 0 4 25 108 0 21 63 549 3 1532 695 1782 808 0 3 ft min O 90 psi 6 bars 0 14 liters sec 3 8 in NPT fitting Maximum loader sizes 4 DL25 2 DL25 2 AR10 4 DL20 2 12 Description 3 DL25 2 DL15 2 DL25 4 DL15 2 DL25 2DL15 3 DL25 2 AR10 2 DL25 4 AR10 4 DL20 2 DL15 4 DL20 2 AR10 front 30 762 0 sq 27 685 8 sq Dimensions shown in inches and mm 26 15 381 0 0152 4 7 16 11 SPECIFICATION NOTES Maximum throughput rates are based on 35 lb ft pelletized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 50 natural 40 natural 5 a
74. ed below the load cell is used as a stop for the load cell to prevent damage if over weighting occurs If this bolt was not loosened during removal or installation it should not need adjusted If it was loosened the gap needs to be reset so the load cell contacts the bolt when the weigh bin is loaded full with material A 020 feeler gage could be used to set the gap N WARNING Electric Shock AN High voltages can cause life threatening currents in the body and injury from elec tric shock Allow only trained and qualified electrical technicians to work on the electrical system Before any electrical work disconnect the unit from the power supply and lock out to prevent unauthorized persons switching it on Troubleshooting 6 11 6 12 Troubleshooting We re Here to Help Conair has made the largest investment in customer support in the plastics industry Our service experts are available to help with any problem you might have installing and operating your equip ment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call INSTANT gt ve BOs 24 HOURS A DAY 7 DATS A WEEK W NOTE Normal operating hours are 8 00 am 5 00 pm After hours emergency service is available at the same phone number From outside the United States call 814 437
75. ed electrical technicians to work on the electrical system Before any electrical work disconnect the unit from the power supply and lock to prevent unauthorized persons switching it on Do NOT use excessive force Forces that are exerted on the load cell from outside when attaching and removing the weigh bin load cell may damage the very sensi tive load cell 1 Position the new load cell 1 both load cells in the unit follow the same proce dure so that the notch on the load cell is facing downward Place a small amount of removable strength Loc tite on the two screws 8 and re attach the new load cell to the mounting bracket 11 Make sure that the load cell is parallel with the chassis wall and the load cell mount ing bracket Tighten to 10Nm 2 Re attach the weigh bin hanger 6 and install the two screws 5 The longer of the two screws should be clos small gap between hanger and weigh bin est to the chassis wall Only snug the screw at this time further adjustment needs to be made before fully tightening them 3 Re install the weigh bin into the blender chassis and position hanger 6 so weigh bin can be removed and installed easily The weigh bin should be installed so it 1s centered in the chassis and does not contact the weigh bin when the cylinder is at rest Once satisfied with placement tighten the two screws 5 to 10 Nm Make sure that nothing is twisted after installation and tightening
76. eigh bin mount or use the existing piece if simply adjusting weigh bin and or weigh bin mount fit Locate the weigh bin and place the new or existing weigh bin mount on the back of the weigh bin Slide the key hole slot on the weigh bin mount the key hole slot should slide into the pins on the weigh bin 4 The weigh bin mount should slide on easily with no interference between the two pieces but should be tight enough so there is very little movement between the two parts The movement shown should be minimal less than 010 of an inch 5 If the weigh bin mount will not slide on the weigh bin the pins that are welded on the back of the weigh bin will need to be adjusted To do this open the weigh bin and place the bin on a vice or similar Once the bin is on a hard surface lightly tap the backside of the pins with a ball head hammer to move the pin outward Each pin should be tapped a few times then repeat step 3 6 If the weigh bin slides on the pins but excessive movement exists greater than 0 010 inch as shown in step 4 they weigh bin pins will need to be tightened To tighten the pins place the weigh bin on a hard surface and lightly tap the top of the pins Each pin should be tapped a few times and then step 3 should be attempted again Continued amp NOTE If the load cell is under tension or dis torted by outside influ ences this can usually be recognized by a flut tering screen A display of 20g or more instea
77. em Setup continued This screen also lists the current firmware version and serial number of the touch screen of the TrueBlend SB 2 system CONAI 615 005 01 Setup System Setup The System Setup screen configures the overall system parameters such as system configu ration recipe entry format alarm database network communications and relays Recipe Setup parameters that select the method with which target throughput data is entered into the system by the user Relays Setup parameters that enable disable relay actions or configure location of I O Alarms Setup parameters that selects the action an alarm takes in the three system operating states Stop Manual and Automatic Network Setup parameters for selecting and configuring remote commu nication ports and protocols System This screen sets parameters that dictate what a system consists of and how the overall system is being controlled Recipe Setup The Recipe Setup parameters select the method by which target throughput values are entered into the system by the user Recipe Setup parameters that select the method with which target throughput data is entered into the system by the user 4 34 Operation Continued Menus System Setup continued The basic recipe parameters are as follows Parameter Secu Detaut Joeri oooO Recipe Entry Method Service Extrusion Extrusion method allows only Natural and Regrind mater
78. en disconnected and or de energized IN WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been removed and all safety guards reinstalled SECTION Description gt ZN What is the TrueBlend SB 2 Blender 2 2 z Typical Applications 2 2 How it works TrueBlend 4 2 3 TrueBlend SB 2 System Components 2 5 Recipe Entry MOdeS 2 5 Resin and Product Names 2 5 Specifications TrueBlend TB45 4 2 6 Specifications TrueBlend TB100 4 2 7 Specifications TrueBlend TB250 4 amp 6 2 8 Specifications TrueBlend TB250 R 4 2 9 Specifications TrueBlend TB500 486 2 10 Specifications TrueBlend TB900 486 2 11 Specifications TrueBlend TB1800 4 5586 2 12 Specifications TrueBlend TB2500 4 5586 2 13 Specifications TrueBlend TB3500 4 55846 2 14 Specifications TrueBlend High Heat Models 2 15 Specifications Level Alarm Control 2 16 Description 2 1 2 2 Description What is the TrueBlend SB 2 Blender The TrueBlend SB 2 blender is a precision gain in weight gravimetric batch blender The ability to precisely control the material blend improves overall quality and reduces material cost Faster automated start up helps create more quality product and gener
79. erformance characteristics Batch size lb 9 Maximum throughput rate lb hr kg hr Bin capacity main ingredient ft liter Bin capacity minor ingredient ft liter Maximum number of materials Number of vertical discharge valves Number size of major bin valves Number size of minor bin valves Dimensions inches mm gt Height above mounting plate Hopper width and depth square Overall depth Control height Control width Control depth Loader center distance Loader center distance Loader center distance Loader center distance Loader center distance Weight lbs kg Installed Shipping Voltage total amps 115V 1 phase 60 hz 230V 1 phase 50 hz Compressed air requirements Discharge valves AcCTroOem7mm uoow Maximum loader sizes 15 inch loaders number of loaders 8 inch loaders number of loaders 2 8 Description Front view Drain chute Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and sim ple cleanout 5 5 2500 950 431 1 6 45 3 1 6 45 3 57 50 1461 36 50 926 40 83 1037 6 50 165 1 8 75 222 3 6 75 171 5 21 81 554 0 20 13 511 2 NA NA NA 320 145 440 200 6 3 3 2 5 5 2500 750 340 2 7 76 4 1 4 39 6 63 0 1600 40 13 1026 42 67 1084 6 50 165 1 8 75 222 3 6 75 171 5 14 88 877 8 20 0 508 9 75 247 7 13 00 330 2 28 00 711 2 400
80. et or screwdriver to loosen the captive retainer 3 Carefully remove the hopper To reinstall the hoppers simply reverse the above steps Once the hoppers have been placed and amp NOTE Upon reinstalling the PP p detachable hopper it is very important to re anchor the respec devices can be mounted anchored the loading receiving tive hopper s using the captive retainer to provide stability during normal operation of the blender 4 78 Operation Continued Changing Material in a Blender Component continued Manual Cleaning Shown with the 1 Turn off the main power and use the disconnect on the power cabinet optional drain chute and safety 2 Disconnect compressed air interlock 3 Open the front access door and remove the weigh bin 4 Position a deflector cardboard tray to divert material from collecting in the mix chamber to and outside drum or bucket e Tip A Conair Drain Chute Accessory is available This allows the discharge valves to be operated in manual mode 5 Using a dowel rod approximately 12 inches long press vertically into the respective valve opening and raise the plunger cone to allow materials to flow from the material compartments Material will flow out of the hopper compartment through the valve opening onto the deflector and into the drum or bucket 6 Discharge the material completely and clean the material hopper from the top down The optional drain chute is av
81. etup Panel Setup This group of screens is used to configure the CPU the touch screen units security level and system date and time Units Setup the numerical units used by the system Security Setup the pass codes for the various security levels as well as settable access rights Continued Operation 4 45 4 46 Operation Menus System Setup Panel Setup continued Panel Sets parameters relevant to the touch screen and CPU Date The current system date and time Panel This screen sets parameters relevant to the touch screen and the CPU a Panel Sets parameters relevant to the touch screen and CPU The basic parameters are as follows AA Name Service TrueBlend The name of the extrusion line This is displayed on the monitor pages and reports Language Operator English English French Default display language seen after Spanish German restart sequence Chinese Contrast Operator 50 10 100 Display contrast The contrast setting of the LCD display Brightness Operator 50 10 100 Display brightness The brightness set ting of the LCD display Screen Operator 0 7200 This is the amount of time that will Saver Time elapse before the display backlight will turn off Touching the screen will turn on the backlight if it is off Valid values are O turn off the screen saver 120 seconds 7200 seconds Continued Menus System Setup Panel Setup continu
82. f the Auto Logout Timeout value is set to a value other than 0 then after the set timeout value has elapsed the current security level number will be set to the minimum level Guest Security Screen To navigate to the Security screen first navigate to the Home page At the Home page press the More button Press the button labeled Security to access the Security screen The security screen displays the current security level and an input box to enter a passcode After entering a passcode a popup will appear indicating acceptance of the passcode This popup is presented for 3 seconds and disappears After the popup disappears navigation back to the Home page or to the Alarms page is possible S NOTE If the passcode entered is invalid the security level will be set to the minimum level The navigation bar on the Security screen also shows a Lock button This button is a quick method to return the system to the minimum security level Pressing the Lock but ton sets the security level to the minimum value without entering a passcode Lock Set the security level to the minimum value without entering a passcode Continued Operation 4 19 4 20 anar EE ES Uperation lj Menus Security continued Security Security Level Passcode af Alarma Current Security Level does MOT permit this action Guest o Passcode Security Invalid Input En
83. g Process 4 3 Stopping the Blending Pr0cesS 4 3 Security Settings aaaea aaa BORGO aS 4 3 2 LICONSA 4 4 SA MENUS emas rgen anaE Oe ER 4 4 MOMO caros asa AE 4 11 RODOS aa ee eee ede baw wae ad ee een o T 4 13 DOCU oa a MAGA Seu eo Rede eee ee ee ee 4 19 PINGING s susana 4 21 TOTS Son ae ame oe ee ee ew ee ee ee ee 4 23 ROCIDOS secas oros ee eae ade eae o t 4 25 Loading Optional 4 31 A vu ak Bees o eke ee eee demas 4 31 Diagnostics oe aa wa Ge we oe ee ee 4 64 Manual COMO 44 tsa Soo ee es woo amp 4 67 IFEMA caninas 4 68 Checking Emergency Stop Function 4 77 Changing Material in a Blender Component 4 78 Cleaning Mixing Chamber and Hopper 4 80 Operation 4 1 The TrueBlend SB 2 Operator Control Panel TrueBlend Recipe PA Home Screen This is the home screen with Batch Mode turned on 4 2 Operation Loading Material into the TrueBlend SB 2 Before the blender can be operated material must be loaded into the TrueBlend SB 2 mate rial hoppers Starting the Blending Process 1 Turn power on to the blender The controller display will come on and the blender Home screen will be displayed 2 Press the Recipe button The TrueBlend SB 2 Recipe screen will appear 3 Enter the recipe percentages for each ingredient 4 Press the Options button and select the material type for each component 5 Press the Au
84. g a 20 kg weight into the bin This weight should stay in place for 10 seconds then be removed Repeat this procedure three times Complete an empty and full calibration see the Operation section entitled Menus Hopper Setup Calibration then operate as normal SECTION Troubleshooting Before Beginning 6 2 A Few Words of Caution 6 2 DIAGNOSTICS How to Identify the Cause of a Problem 6 3 Signaling Alarm Message 6 3 Handling Alarm Messages 6 3 PUIG os eae oe CR Hae eee ee ee ee h 6 4 REPAIR Replacing Fuses 0 00008 6 11 Replacing Controller Battery 6 12 Replacing Load CellS 6 13 a aj q 2 0 5 gt F gt e Troubleshooting 6 1 6 2 Troubleshooting Before Beginning You can avoid most problems by following the recommended installation and maintenance procedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and how to fix it Before you begin troubleshooting Find the wiring diagrams and other schematics that were shipped with your equip ment These diagrams are the best reference for correcting a problem The diagrams also will note any custom features such as special wiring or control options not cov ered in this user guide Verify that you have all instructional mater
85. ghten the screws on the plug e Tip The cable end with the wire exiting from the side should be connected to the touch screen HMI operator panel to allow the screen to tilt freely e Tip Remove the protective film on the touch screen control for optimum performance Installation 3 5 3 6 Installation Layout of the Material Hoppers 4 position Position 1 amp 2 Main components Position 3 amp 4 Additive components Position 3 A Front door mix chamber Position 1 amp 2 Main components si Position 3 amp 6 Main or additive _ O position components Position 1 Position 2 Position 4 amp 5 Additive components Position 3 Position 6 Se Position 5 Position 4 Mounting the Loaders 1 Install the loaders receivers onto the blender bins 2 Supply power to the loader as needed Refer to the manu al the came with your loader for specific instructions 3 Supply compressed air to the loader as needed Refer to the manual the came with your loader for specific instructions 4 Refer to the wiring diagrams that were shipped with your blender and loaders Connecting Compressed Air 1 Connect the air hose A to the compressed air connection of the unit B Connect a clean dry compressed air supply to the compressed air con nection on the blender You will need to supply 1 4 inch male NPT fitting to make the connec j i j SAT tion Adjust the regulator to 90 psi pe 0 p ei Que 2
86. gs from the last solenoid on the stack Connect the hose that goes to the rear of the cylinder to the bottom of the valve stack and connect the hose 4 that goes to the front of the cylinder to the top of the valve stack Make sure that the hose is fully seated into the fitting Close control box door and re connect the air and power to the unit Make sure no leaks are present Place the blender manual mode and operate the FCV Make certain that the valve is Operating the way the manual indicates if indicates open valve is open and if indi cates closed the valve is closed If not correct switch hoses inside the control box 10 The valve should retract at full speed and extend fully in about one second If this is not set correctly loosen the locking nut 12 on the throttling valve on the front of the cylinder and adjust as necessary Once this is adjusted correctly re tighten the locking nut to make sure that this speed does not change E 1 Appendix Installing Dry Air Blanket Option En den Disconnect and lockout the main power supply and the air supply from the blender Bolt the inlet air adaptor to the bottom of the blender Organize the piping from the dryer to the blender Loosely make all connections between the blender and the dryer making sure to install the slide gates where necessary Tighten all connections Follow instructions in the blender user guide and the dryer user guide for test ing the insta
87. have a picture frame border around a light blue box with black text Boxes that are currently locked will have a picture frame border around a dark brown box with white text When inputting a numerical field the keypad will indicate the minimum and maxi mum values of the field next to the displayed value The minimum number is on the bottom with the maximum number on the top The left most button in the navigation bar is an Alarms button Pressing this button on any screen of the system will immediately display the active alarms screen Pressing the Back button on the alarms screen will return the screen displayed before going to the alarms screen The Alarm button will change color to reflect the severity of the most severe active alarm in the system Recipes are numbered from 1 to 1000 Resins are numbered 1 to 250 Continued Operation 4 5 M enus continued Keypad Alpha Numbers 4 6 Operation Continued M enus continued Keypad Alpha 2 Screen Continued Operation uoijelado Dv 4 7 4 8 Operation M enus continued Are You sure Popup Are you sure Screen Navigation Screen navigation is accomplished by pressing buttons visible on the command bars shown at the bottom or right hand sides of the screen Each button appears as a raised area and is represented with an icon and name When the button is pressed it will change color
88. i cates that this problem is occurring because of bin number 2 There are 3 basic types of alarm codes Common alarms material position specific alarms and loader option alarms Alarm displays alarm messages for Batch Hopper Components and Mixer The basic alarm messages are listed on the following pages 6 4 Troubleshooting Continued Basic Alarms Alarm Message Batch Hopper is not dumping Batch Hopper cannot run in Gravimetric mode Hopper hardware failure Mixer door is open Component hopper out of material Possible Cause Batch weigh hopper exit gate is not opening and closing properly and all the material is not allowed to exit Mixer proximity switch is not operating leav ing no room for material to fully exit the batch weigh hopper Mechanical inter ference with the batch weigh hopper is preventing the weight of the hopper to detect as empty The batch hopper weight is unstable and cannot weigh properly May be caused by mechanical interference of batch weigh hopper or excessive machine vibration The load cell or the load cell input PLC Slice is bad Occurs when the mixer door interlock is broken door is opened Occurs if the component hopper does not dose any material Solution Ensure the batch hopper exit gate fully opens and closes properly Test and adjust mixer proximity switch so the material from the batch weigh hopper is allowed to drain fully into the m
89. ial types Injection method allows Natural Regrind Additive Natural and Additive Batch material types Component Entry Service Percent Parts Layer entry values correlate to a simple ratio Options to the other layers Percent Layer entry values correlate to a percent age of total and together all layers must add to 100 Use Order Names Service In reports and on the monitor screens the system is capable of showing a job order name This is for dis play and reporting purposes only Use Resin Names Service The system can keep track of resin usage if resin names is enabled This option requires the selection of a resin for each layer target entry The resins have an assigned density value which may be used depending on the recipe entry method Feed Order In Recipe Service The order in which the components feed can be con trolled by the operator using the recipe If this is set to Yes then the recipe entry will require a feed order Recipe Entry Method Component Entry Options Pa T T x Setup System Recipe Basic Continued Operation 4 35 4 36 Operation Menus System Setup continued The advanced recipe parameters are as follows ee Density Part of Recipe Service No Yes forces recipe to ask the g cc value of each com ponent in the recipe Regrind Out of Material Service Continue Should an empty regrind component allow the blender to Continue no alarm Cont
90. ials related to the TrueBlend SB2 its con trol systems and its components Additional details about troubleshooting and repairing specific components are in this manual e Verify that you have the user manuals for the equipment located upstream and down stream from the TrueBlend SB 2 system Solving problems related to material con veyed to the TrueBlend SB 2 or due to poor extrusion or injection quality may require troubleshooting malfunctions or incorrect operating procedures on other pieces of equipment on the production line A Few Words of Caution WARNING This machine should be adjusted and serviced only by qualified technical per sonnel who are familiar with the construction and operation of this type of equipment DANGER Voltage Hazard Always disconnect and lock out the main power supply before opening the TrueBlend SB 2 electrical enclosure Troubleshooting procedures that require access to the electrical enclo sure while the power is on should be performed only by qualified electrical technicians who know how to use electrical testing equipment and understand the hazards involved Improper corrective actions can lead to hazardous conditions and should never be attempt ed to sustain production How to Identify the Cause of a Problem To find the cause of an alarm go to the Main Menu Home screen and press the ALARMS key The cause of the alarm and the time that it occurred will be displayed on the screen
91. iate attention Ack Acknowledges alarms in the active alarm list If the alarm is inac tive then it will be cleared from the list Log Navigate to the logged alarm page Clear Clear the logged alarm list of all entries Report Send the logged alarm list to an output device such as a printer or USB thumb drive Continued Operation 4 21 4 22 Operation Menus Alarms continued For each alarm in the alarm list information fully describes the alarm state and time of occurrence Each alarm is color coded to indicate its severity Severity 1 Information Green 2 General Yellow 3 Shutdown Red The time the alarm occurred Alarm State Active The alarm is occurring currently Inactive The alarm is no longer occurring Acknowledge State An indication if the alarm has been acknowledged NOTE The alarm may still be active and be acknowledged A descriptive text of the device and the alarm In the lower center of the screen is an Alarm Filter pull down menu With this filter the user can select to show all alarms General Shutdown alarms only or Shutdown alarms only If the number of alarms exceeds a single screen touching the alarm list displays a scroll keypad to allow scrolling of the list Alarms Scroll Keypad Alarm Alarms Active Continued Menus Alarms continued Alarm Log Alarms Logged Menus Totals Totals The totals screen
92. ical cone valves and are fed into the weigh bin which is mounted on a load cell The pneumatic cylinder opens the weigh bin The mixture batch falls into the mixing chamber and is mixed and agitated by an electrically powered mixer into a homogeneous state The mixing chamber holds three batches After mixing the chamber is emptied by the discharge slide gate into the injection or extrusion process sN Material is dispensed into each material hopper by a hopper loader Next the vertical valves dispense the pro grammed amount of material into the weigh bin The load cell deter mines when the batch is complete and the pneumatic cylinder drops the batch into the mixing chamber The batch is mixed by the electrically powered mixer O The discharge slide gate is opened and the mixture is emptied D Note After the slide gate discharges the mixture approximately one batch remains in the mixing chamber to ensure that the next batch can be optimally mixed This drawing is being used to facilitate the understanding of how the blender works and is not an actual representation of your blender 2 4 Description TrueBlend SB 2 System Components The TrueBlend SB 2 blender is comprised of a number of separate components each having a specific function as described below e TrueBlend SB 2 Controller This is the overall brain of the system An easy to use intuitive LCD touch screen controller wi
93. ieve the resins from a USB thumb drive Retrieve Resins Retrieve the resins from a USB thumb drive Retrieve Resins Retrieve the resins from a USB thumb drive Continued Menus Trending continued Diagnostic Trending Feed Trend Trending Feed Trend The default Feed Trend device is the Batch Hopper weight This can be changed to a com ponent hopper by touching the arrow down key to select a different device Touching the More button brings up the cursor screen With the cursor screen shown the plot will not auto update This allows the user to move the cursor to a specific desired data point Touching the chart a second time will exit the cursor screen Use the horizontal command bar to move the cursor across the chart The data points present at the cursor point will be displayed in the boxes along the right hand side of the screen The boxes rep resent the data for extruders to 12 from top to bottom Continued Operation 4 69 4 70 Operation Menus Trending continued Feed Trend Trending Cursor Control Menus Diagnostics Diagnostic Batch Hopper This page provides information regarding the stability of the batch hopper itself The stable weight field indicates if the blender CPU has qualified the batch hopper weight stable enough to make batches This field is YES when the batch hopper weight it stable Delta Grams field indicates and variation or vibration that is occurring on the bat
94. ill display a list of problems with the recipe Continued Operation 4 25 4 26 Operation Menus Recipes continued For a blender there is a recipe options page On this page the component feed order can be set if configured as well as the type of material in the hopper Natural Regrind Additive Natural Additive Batch Note Additive Natural and Additive Batch only appear as choic es if the Injection Recipe Entry mode is set To set it go to Setup System Recipe and select the recipe entry method It is possible to set the blender to process a certain amount of material and then stop this is called Job Mode This mode is first enabled from the blender recipe screen press Job to show the setup screen Enable Job Mode by pressing the On button Set the Target Weight to the amount of material that should be mixed Press the Clear button to reset the Current Weight field Now when Auto is pressed the blender will generate the target weight of material and stop The blender can be stopped and restarted and the current weight field will be maintained so that the right amount of material in the batch is generat ed The blender Home page will also show the status of the Job Mode The Recipe Book contains any stored recipes In the Recipe Book recipes can be edited or viewed without affecting the current running recipe The proper security level must be met in order to
95. ing Voltage total amps 115V 1 phase 60 hz 230V 1 phase 50 hz Compressed air requirements Discharge valves Maximum loader sizes 8 inch loaders 2 6 Description 32 50 825 5 25 00 635 27 00 686 6 50 165 1 8 75 222 3 6 75 171 5 12 75 323 9 12 91 327 9 1 0 0 5 90 psi 0 2 ft min 6 bars 0 09 liters sec 1 4 in NPT fitting Number of loaders 4 GRAVIMETRIC BATCH BLENDERS TRUEBLEND TB 45 4 Top views Dimensions shown 1 25 32 Mixing chamber access door in inches and this side of the interface mm diameter centered 45 O 75 00 Mounting bolt hole size 4 holes 7 16 inch 11 0 mm Predrilled 5 x 5 mounting pattern as standard Maximum throughput rates are based on 35 lb ft pel letized material using all standard valve sizes Use of reducer inserts will lower the rate shown Throughput rates are based on e A 4 position blender recipe of 20 regrind 80 natural 3 color and 2 additive material The optional flow control valve will mount inside the chassis in the space of the manual slide valve Conair recommends using the optional flow control valve when mounting the blender on a stand surge bin or hopper Hopper positions three and four are supplied with eight inch cover plates as standard Numbers in top view drawings represent hopper posi tions Specifications may change without notice consult with a
96. ing a full adjustment material present does not change the empty adjustment fe face Threaded sleeve LED ring yellow Programming buttons Calibrating with material present 1 With material present use a small screwdriver or pen and press the OUT OFF adjustment push button until the yellow LED ring flashes at a rate of 1Hz this should take about 2 seconds Release the OUT OFF button and the yellow LED ring will turn off The sensor is now set for the mixing chamber with material present IMPORTANT do not adjust the OUT ON LED this will change the operation of the level sensor and it will no longer work for this application 5 8 Maintenance Continued Replacing Pneumatic Cylinder on Vertical Dispense Valve Assembly 1 Open the cover 3 amp S _ NOTE When disassem bling the cylinder valve assembly measure the length of the complete assembly Dim A and record This assembly length must be main tained When reassem bling adjust the length to this value Loc tite all fittings when reassembling 2 Remove the cylinder cover 4 3 Pull the hoses 1 from the cylinder 4 Remove the nut 2 5 Remove the complete unit 6 Reassemble in reverse order Note the stroke when installing otherwise the desired throughput may not be reached Continued Maintenance 5 9 amp NOTE Items number 5 and 6 are used as a stop for the load cell to prevent damage if over weigh
97. inue with Alarm Remove and Continue or Stop with Alarm Recipe Density Part of Recipe Regrind Gut of Material Action Continue 3 Setup System Recipe Advanced Relays Setup This page 1s used to set up the system configurable relays The relays that are configurable are as follows auto hand input relay on TrueBlend EXT Only controlled off hand control system running output relay ON when system drives are running Relays Setup parameters that enable disable relay actions or configure location of I O Continued Menus System Setup continued When pressed a pull down menu of available relays and relay parameters can be changed Select the relay from this list displays the specific parameters for that relay The enable relay parameter is only available for some relays The basic parameters are Description The X20 slot number where the relay is connected The X20 input location on the assigned slot Enable Relay Service No Relay dependent If this field is available it will enable disable the relay function o Relays selected Relay Setup System Relays Menus System Setup Alarms Alarms Setup It is possible to customize the severity and actions of all alarms in the system This screen also has a Defaults button This button will reset all of the alarms severity back to the default factory state This will not affect any other setup parameters Alarm Set
98. ior to September 2007 The level sensor switches when material passes in front of the active area The level sensor adjustment depends on the type of material and must be adjusted accordingly These instructions are for calibrating a sen sor with material present For most applications setting the sensor with the vessel empty is sufficient You can if you wish make additional adjustments with material present in the bin Making a full adjust ment material present does not change the empty adjustment This type of adjustment may need to be completed for low bulk density materials The green LED flashes slowly approx 1 Hz After approx 5s it flashes faster approx 2 Hz unit is in the programming mode Press the button and keep it pressed 5 10s The yellow and green LED s are lit l j C4 unit is set and is in the operating mode Now release the button With material present press and hold the pushbutton adjustment with a pen or a small screwdriver for more than 5 seconds but less than 10 seconds For the first 5 seconds the green LED will flash slowly approx 1 Hz or 1 flash per second after approx 5 seconds then it will begin to flash faster approx 2 Hz or 2 flashes per second Release the push button as soon as the green LED begins to flash faster approx 2 Hz or 2 flashes per sec ond Appendix D 2 Installing Automatic Flow Control Valve Option 1 Disconnect and lockout the main power
99. itches A compo nent hopper proximity switch is not covered Each component is programmed to dose very accurately Alarm occurs if the dosed amount has an error greater than Setup Component Alarm Out of specification Setpoint Occurs if a component material dosing valve leaks material when it is sup posed to be closed Occurs if a material dosing valve sud denly doses material at a rate that is significantly different than a prior dose rate Only occurs if blender has Loading Option Hardware and Loading Option Software is enabled Alarm occurs if the receiver fill time exceeds the alarm time set in Loading Setup Loader Time Alarm Time Set point Only occurs if blender has Loading Option Hardware and Loading Option Software is enabled Alarm occurs if there are TWO blenders being loaded with ONE vacuum Pump AND the Ethernet communication link between the two blender touch screens has failed Solution Check the component hopper to be sure material is present Adjust prox imity switch for proper operation Correct component hopper loading problem This usually occurs if very LOW per centage doses are attempted The valve for this low dosed component may be too large Increase the Setup Alarm parameter called Out of Specification for that component Setup Component Alarm Consult the factory for additional assistance Check each component material dosing valve to ensure it is not held o
100. ixer Eliminate all mechanical interference with batch weigh hopper In Setup Component Advanced the Parameter Hopper empty weight toler ance default value is set too low Eliminate mechanical interference or vibration first Next verify the empty weight displayed for the batch hopper is stable Look at Delta Grams value under Setup Diagnostics Batch Hopper This is the amount of weight variation the computer sees Edit the setup value under Setup Batch Hopper Advanced called Unstable Weight Tolerance Increase this value slightly to make the alarm go away Calibrate the hopper A zero value near 2 000 000 should also show up during the Zero part of the calibration If a value greater than 8 388 608 is dis played during the weight part of the calibration replace the load cell Close and make the door interlock Occurs in conjunction with Mixer Door Open as this breaks the 24vdc inter lock to the PLC Input Slice Check the component hopper to be sure material is present Correct com ponent hopper loading problem Continued Troubleshooting 6 5 Basic Alarms continued Alarm Message Component hopper low on material Component out of specifi cation Gate valve failure Material feed error Receivers material demand exceeds alarm time Component hopper out of material Troubleshooting Possible Cause Occurs ONLY with optional component hopper proximity sw
101. l the power supply be terminated Alarm State During an alarm condition this outlet will energize any 110V 220V remote alarm indictor that is The Level Alarm Control module s capacitance sensors are positioned connected This out within a blender s material bin sight glass to provide adjustable material let will not have level detection The sensor can be positioned high on the sight glass power at any time left image to monitor material levels of high throughput applications or other than during low on the sight glass right image to monitor material levels of low or alarm conditions less critical throughput applications Description SECTION Installation Unpacking the Boxes 3 2 Preparing for Installation 3 3 z Preparing to Mount the Blender 3 4 zO Mounting the Blender 0 00000 was 3 5 Mounting the Control 3 5 Layout of the Material Hoppers 3 6 Mounting the LOaderS 3 6 Connecting CompressedAlil 3 7 Installing the Weigh BIN 3 7 Connecting the Main Power 3 7 Testing the Installati0N 3 8 TrueBlend SB 2 Batch Hopper Calibration 3 9 Installation 3 1 3 2 Installation Unpacking the Boxes Upon receiving the shipment always perform a thorough inspection of the contents and compare it
102. late the equipment from the electric power Turn the rotary disconnect switch to the OFF or O position 3 Secure the device with an assigned lock or tag Insert a lock or tag in the holes to prevent movement 4 The equipment is now locked out aN WARNING Before removing lockout devices and returning switches to the ON position make sure that all personnel are clear of the machine tools have been removed and all safety guards reinstalled To restore power to the dryer turn the rotary disconnect back to the ON position 1 Remove the lock or tag 2 Turn the rotary disconnect switch to the ON or P position D Note Depending on model your blender may have either of the disconnects shown Introduction 1 5 1 6 Introduction Zero Mechanical State ZMS AN CAUTION Before performing maintenance or repairs on this product you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start up A lockable device has been provided to isolate this prod uct from potentially hazardous electricity During maintenance it is essential that the system be put into a state which eliminates the possibility of components making an unexpected and dangerous movement This procedure is typically referred to as lockout After all energy sources have been neutralized the system is in the zero mechanical state ZMS This provides maximum protection against unexpect ed mechanical mo
103. ll then appear in the Recipe Book for storing each new resin name The resin name choices that are stored in the recipe book will then appear on the Recipe page Continued Menus Recipes continued Recipe Resin Mame Resin 1 Density Recipe Resin Select Material Calibration Recipes Material Calibration The current production recipe can be saved to the Recipe Book With the blender in Automatic press the Book button on the Recipe page then press the Upload button After the Upload button is pressed on the recipe page the user must enter a recipe number and name Pressing the Save button will save the recipe at the location specified by the recipe number S NOTE Any recipe at that recipe number location will be overwritten with the new recipe values The recipe inventory total is however not cleared If the recipe number has changed the user will be asked if the newly stored recipe should become the current production recipe This is important for tracking recipe totals If the recipe name changes then the current production recipe name will change to match that of the newly entered name Continued Operation 4 29 4 30 Operation Menus Recipes continued Enter the Mame and Mumber of the recipe and press the Save button Recipe Save Current Recipe Book The recipe book is the depository for all 1000 stored recipes It is here that recipe
104. llation Run the dryer and check for leaks Appendix F 1
105. ly distributed the mixing unit may tip and injure people when it is lifted Preparing for Installation The TrueBlend SB 2 blender is easy to install if you plan the location and prepare the mounting area properly 1 Make sure the mounting area provides O A grounded power source supplying the voltage and correct current for your model Check the blender s serial tag for the correct amps voltage phase and cycles Any field wiring should be completed by qualified personnel to the planned location for the blender All electrical wiring should comply with your region s electrical codes D Note Electrical supply must be a clean power source with nothing else on the circuit for example self loading loaders The unit must be grounded to a lug by the sensor on the back of the unit O Clearance for safe operation and maintenance O A compressed air supply It is necessary to supply compressed air to the blender Your plant system must be capable of supplying at least 0 6 MPa 87 psi 6 0 bar D Note No additional compressed air consumers may be connected to the unit because this may reduce operating pressure If the operating pressure is less than 0 6 MPa 87 psi 6 0 bar the loading precision may be affected Installation 3 3 3 4 Installation Preparing to Mount the Blender The blender can be mounted on the throat of the processing machine or operated as a cen tralized mixing station and mounted to an optional st
106. m Configuration Parameters are for TrueBlend EXT Only See The TrueBlend EXT User guide for complete information Application Service Stopped Extruder Service control mode Stopped Hauloff Service control mode Stopped Service Stopped Number of additives Use Service Regrind Stopped Scrap in extruder Blown Film Control Blown Film Sheet Wire and Cable Pipe and Tubing Profile Unused Monitor Control Unused Monitor Control Yes No The type of extrusion system being con trolled Affects recipe entry The control mode of the connected extruders Control extruder speed is controlled by True Weigh system Affects Recipe entry The control mode of the product take away device Control the speed of the take away device is controlled by True Weigh System Affects recipe entry The total number of material additive devices present in the system Used on TBEXT Models Only When enabled the scrap percentage becomes part of the extrusion recipe Continued Menus System Setup Configuration continued EN MEE Application Blown Filmi d Extruder Control Mode Unusedk J Nip Control Mode Unusedk J Humber of Additives Use regrindfscrap in extruder Setup System System Changed made to the configuration affect the recipe entry method Select a new recipe entry method Setup System System Recipe Menus System Setup Panel S
107. nder and explains step by step how to install operate maintain and repair this equipment Before installing this product please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet You also should review manu als covering associated equipment in your system This review won t take long and it could save you valuable installation and operating time later How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation Symbols within triangles warn of conditions that could be hazardous to users or could damage equip ment Read and take precautions before proceeding Numbers indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout the manual Your Responsibilities as a User You must be familiar with all safety procedures concerning installation operation and maintenance of this equipment Responsible safety procedures include Thorough review of this User G
108. ng it into another touch screen system will trigger the license to be invalid and the system will not complete the boot sequence If the license is invalid the user is presented with an invalid license popup window Contact Conair support to obtain a new license Quick Setup For an initial setup a Quick Setup procedure is available This is an intelligent process where the user is asked a series of questions that will configure the system The two basic steps in this procedure are configuring the basic system and extruder weigh hopper config urations To start the Quick Setup procedure first navigate to the Home page At the Home page press the More button Press the button labeled Setup followed by more button then the Quick Setup button Hardware This section outlines some of the details of the PLC Hardware Battery The TrueBlend SB 2 touch screen uses battery backed memory to store a variety of control and status data If the battery drains to a low voltage a system alarm will occur to inform the user If the battery is drained and power to the system is removed the data stored in battery backed memory will be lost To avoid this once the alarm is occurring replace the battery with system power applied The battery is Conair Part Number 2671080303 This battery is replaced by removing the battery cover and pulling on the plastic tab to extract Take care when inserting the battery that the
109. ning of the blender for fast and simple cleanout MODELS TB500 4 TB500 6 Performance characteristics Batch size Ib g 11 5000 11 5000 Maximum throughput rate lb hr kg hr 1500 680 1150 522 Bin capacity main ingredient ft liter 2 7 76 4 2 7 76 4 Bin capacity minor ingredient ft liter 2 7 76 4 1 35 38 2 Maximum number of materials 4 6 Number of vertical discharge valves 4 6 Number size of major bin valves 2 100 60 mm 2 100 60 mm Number size of minor bin valves 2 30 mm 4 30 mm Dimensions inches mm NOTE Side and front view draw ings are model TB500 4 The bin positions change for a TB500 6 see the top view MOUNTING INTERFACE Dimensions shown in inches and mm Mixing chamber access door this side of the interface 3 5 32 diameter 80 gt ASCSTIOn mmoouw Height above mounting plate Hopper width and depth square Overall depth Control height Control width Control depth Loader center distance Loader center distance Loader center distance Weight lbs ko Installed Shipping Voltage total amps 115V 1 phase 60 hz 6 3 6 3 230V 1 phase 50 hz 3 2 3 2 Com ressed air rec Loader center distance Loader center distance uirements 63 00 1600 40 13 1026 43 00 1092 6 50 165 1 8 75 222 3 6 75 171 5 22 00 558 8 22 00 558 8 NA NA NA 400 182 520 236 63 00 1600 40 13 1026 43 00 1092
110. of air 1s bleeding from the opening in item 1 Adjust the insertion level and direction of item so the air is blowing across the face of the sensor Insertion depth into the chamber should be minimal as possible so tube does not contact mixer blade tighten item 8 on item 1 MAKE SURE TUBE SLOT IS AIMED AT SENSOR MAKE SURE TUBE DOES NOT INTERFERE WITH MIXING BLADE BEFORE TIGHTENING COMPRESSION FITTING INSTALLATION EXAMPLE 5 TB100 SHOWN Tra 5 7 a a h A 4 DI A j SL le AA o e E O SA DS a DNS Ss FE SY 2 Hole Locations for Blow Off Kit HOLE LOCATIONS FOR BLOW OFF KIT BY BLENDER MODEL 1 5 8 DRILL amp TAP 1 8 NTP DRILL 8 TAP TB45 TB100 1 8 NPT DRILL amp TAP 148 NPT TB500 ALL DIMENSIONS ARE TAKEN FROM THE EDGES OF THE BACK PLATE NOT THE HOUSING DRILL amp TAP 1 8 NPT TB250 TB250 R Appendix C 2 D 1 lt S NOTE Do not hold the button longer than 5 sec onds Holding 10 sec onds locks the sensor Appendix Calibrating Adjusting Level Sensor Pre September 2007 This style material sensor used prior to September 2007 The level sensor switches when material passes in front of the active area The level sensor adjustment depends on the type of material and must be adjusted accordingly These instructions are for calibrating a sen sor with no material present LED green flashes unit is in the programming mode
111. of removable strength Loc tite onto the two screws 2 and re install the load cell and weigh bin mounting bracket back onto the load cell mount 7 Make sure that the load cell 4 is mounted square with the load cell mount 7 and tighten the two screws 2 to a value of 10 Nm Assemble in reverse order Load Cell Removal and Installation Models 1B045 15100 continued To complete the installation of the load cell it is necessary after installation to pre stress the load cells 1 Place a 3kg weight into the load cell for 10 seconds and then remove it 2 Repeat this procedure three times 3 Re route and install the wiring from the load cell to the appropriate location in the control box 4 Complete an empty and full calibration see the Operation section entitled Menus Hopper Setup Calibration and operate as normal Weigh Bin Mount Installation and Adjustment Models TB045 amp TB100 Follow these steps to install and adjust the weigh bin and or the weigh bin mount on TrueBlend models TB45 and TB100 Use this procedure to fit a new weigh bin mount to an existing weigh bin or to adjust the clearance between the weigh bin and the weigh bin mount 1 Remove the weigh bin from blender and set aside 2 While holding the load cell in place to minimize twisting or bending of the load cell remove the two screws that hold the weigh bin mount to the load cell 3 Remove the weigh bin mount and discard if installing a new w
112. on recipes of the products to be made There can be up to 1000 different product name recipes and each name can be com prised of a 12 character alphanumeric name The TrueBlend SB 2 controller will keep a complete inventory for each of the product names The use of the resin and product names is optional and must be enabled or disabled from the recipe set up menu screen From the Home Screen press More Setup System Recipe From this screen you set Use Resin Names to YES If this is enabled names must be in the recipes from the Recipe screen Description 2 5 TPBX024 0911 SPECIFICATIONS Side view Front view a J AT Drain chute SS Purchase the optional material drain chute that readily installs to the chassis opening of the blender for fast and sim ple cleanout MODELS TB45 4 Performance characteristics Batch size lb 9 Maximum throughput rate lb hr kg hr Bin capacity main ingredient ft liter Bin capacity minor ingredient ft liter Maximum number of materials Number of vertical discharge valves Number size of major bin valves Number size of minor bin valves 2 40 mm 2 20 mm Dimensions inches mm Height above mounting platet Hopper width and depth square Overall depth Control height Control width Control depth Loader center distance Loader center distance Weight Ibs kg Installed Shipp
113. or control mode has specific requirements for the data entry Continued Operation 4 43 4 44 Operation Menus System Setup Configuration continued The recipe entry question will appear as a popup after an attempt is made to exit the screen Select a recipe entry method then press Close to exit the popup The user may now exit the screen normally This entry can be changed later from the Recipe Setup screen if nec essary The basic system configuration parameters are Number of Service Components Stopped Product Service Model Stopped Loading Service Enabled Stopped Self Cleaning Service System Stopped Available Service Stopped Material level Sensors Available System This screen sets parameters that dictate what and how the over all system will be controlled Depends upon The number of components for the Product Model Product Model chosen TB45 4 Various The product model will set up various parameters for all of the components and the batch weigh hopper No No O Yes No Enable self loading Once this has been changed to YES the operator will be asked to enter an unlock key Yes No Enable self cleaning Once enabled the blender is capable of interfacing to the optional self cleaning feature N Yes No Enable Component Material Level Sensors Once enabled the blender is capable of interfacing to the optional Material Level Sensors The Advanced Syste
114. ossible with a summary status report This report can be sent to a printer on a periodic basis but to the printer ONLY It is intended for this report to be printed at shift change in order to report the shift inventory totals However this report can be printed on any periodic interval The setup for this process requires FIRST for the proper time to be entered into the touch screen in the Setup Panel Date advanced page Logging Select Compact Flash Select the destination where the report should go Destination USB 1 USB 2 Batch Report OFF or ON Select ON to begin logging batch data to the report destination Continued Operation 4 17 Menus Reports continued atch Report Name Totals 1 MOTE Press Save to accept settings Reports Logging TB Reports TrueBlend Reports Software Required Shift Inventory Report OFF or ON Select ON to output data to TB Reports Batch Report OFF or ON Select ON to output batch data to TB Reports Scale Report OFF or ON Select ON to output Scale data to TB Reports Alarm Report OFF or ON Select ON to output Alarm data to TB Reports Recipe Report OFF or ON Select ON to begin logging Recipe data to the report destination YW Shift Inventory Report Report Start Time HH Mihi Report Interval Time HH tht A i Batch Report MY NIT TrueBlend Reports 4 18 Operation Menus Security Security Security levels dictate what data is accessi
115. pe The blender Home page also shows for each hopper the material type in the hopper the set and actual target values for the hopper as well as an indicator that show the hopper is cur rently feeding The batch hopper has indications for batch weight alarming and gate open The mixer has indications for mixer proximity sensor mixer alarm and mixer turning In Job Mode the blender will run producing a blend for a set amount of material and then stop The Job Mode indicator box shows the set and actual batch totals as well as the per cent completion Pressing this box the user will be taken to a screen where Job Mode may be disabled or the target weight can be edited If this box is not being show Job Mode has been disabled To Re enable Job Mode go to the blender recipe and press Job Mode Automatic Places the Blender into automatic operation Requires valid recipe entry from the Recipe button The button will show a green indica tor if in automatic Stop This button is used to put only the blender into a stopped state The button will show a red indicator if stopped Totals Navigate to the material throughput totals screen Monitor Navigate to the Monitor Detail screen Recipe Navigate to the recipe entry screen Continued Operation 4 11 Menus Home continued Security Navigate to the security passcode entry screen Setup Navigate to the setup
116. pen or leaking material Check the component material dosing valve to ensure it indexes open and closed properly Check the material within the component hopper for mate rial bridging or bridging from an obstruction In the Recipe screen reset the Material Calibration of the problem component and monitor for recur rence Check the component hopper to be sure material is present Correct com ponent hopper loading problem Repair the Ethernet Communication link between the two blender touch screens Basic Alarms Alarm Message X20 slice is bad Hopper gate valve failure Calculated batch size is greater than capacity continued Possible Cause Power or Communications has been lost to the PLC Slices in the blender electri cal panel Batch Weigh Hopper is not dumping material The batch size is automatically adjusted by the computer to produce the best blend ratio possible If the new calculat ed batch size is greater than the setup parameter Setup Batch Hopper Over size Batch then this alarm occurs Solution Occurs if 24vdc is removed or X2X network communication is lost from touch screen Also occurs in conjunc tion with Mixer Door Open as this breaks the 24vdc interlock to the I O PLC Slices Display batch weight on Home Screen to be sure weight displayed is less than 0 15 lbs when empty of material Calibrate Batch Hopper This usually occurs if very LOW per centage doses
117. power on and make sure that all mixing components are in place and close the door 4 Use a small screwdriver or pen to press the OUT OFF adjustment pushbutton until the yellow LED ring flashes at a rate of 1Hz This should take about 2 seconds Release the OUT OFF button and the yellow LED ring will turn off The sensor is now set for emptying mixing chamber and should need no further adjustment IMPORTANT Do not adjust the OUT ON LED this will switch the operation of the level sensor 5 Hold a finger over the front of the sensor and make sure that the yellow LED ring illuminates to indicate that the sensor is functioning properly 6 Operate the mixer manually to ensure that the yellow LED ring does not light when mixer blade passes the face of the sensor ef Tip If this does occur make sure the sensor is inserted flush with the rear plate of the mixing chamber If the unit still sees the mixer while in operation turn the mixer blade to the position where the sensor is sensing the blade and repeat step 4 This will adjust the sensitivity of the sensor so that the blade is invisible but the material will still be sensed during operation Maintenance 5 7 Calibrating Adjusting the Sensor continuea For most applications setting the sensor with no material in the vessel is sufficient A large amount of fines or regrind or a low bulk density material may require calibrating or adjust ing the sensor with material present in the bin Mak
118. pt the data into the input box User Interface The user interface presented on the touch screen is a collection of pages or screens which can be used to monitor and control the system The TrueBlend SB 2 system is designed to work with a variety of configurations and applications As a result screen pages will vary depending upon the configuration of the system General Concepts Useful concepts for operating the TrueBlend SB 2 system All user interaction is through the touch screen display Navigation is processed via pressing raised 3D shaped buttons Pressing a button will appear to indent the button indicating a button press Numeric and character entry is performed by touching an input box which reveals an alpha numeric keypad An input repeat feature occurs if a character is pressed and held The Numeric only keypad will display the minimum maximum values allowed for the particular data field to be edited If data is entered outside the listed range the data will reset to the range limit nearest the entered data value Parameters for display only will be presented within a box with a light yellow back ground A value represented with black text is an Actual value learned by the sys tem A value represented with blue text is a value Set by the user Boxes that allow user input have a picture frame border around a dark blue box with white text The currently selected input box will
119. r the given Time value Set indicates the set amount to feed Actual indicates the actual amount dosed Feed count indicates the number of dose feeds conduct ed to obtain the actual amount fed The Set Tolerance value in grams indicates the absolute minimum amount of material the gate is capable of dosing Press the or button to view the next component a Component 1 Diagnostic AA Feed Count Set Tolerance i Diagnostic Component Continued Operation 4 71 4 72 Operation Menus Diagnostics continuea The Diagnostic Component Weight screen allows the user to specify an exact amount of material to dose as a test of the valve and weigh system This is useful if a particular resin 1s required to dose a very low percentage or is of an unusual geometry or size The user can use this screen to determine the overall capability of a component valve and a material to dose The user can select the Number of dose tests the test weight to dose the weight tolerance or accuracy desired The material calibration or material feed characteristics can be cleared before the dose test is begun here as well Press OK to begin the dose test after set ting the prior fields Press the Weight Results screen to observe each dose test ee Se Number of tests Test Weight Weight Tolerance Clear Mat Calibration Minimum Dos DES m Range Total Target J Total Te st Total Weight f Diagnostic
120. rect feeds Setup 5 1 10 Force alarm if number of feeds are before alarm out of spec Quantity of no material feeds Setup 5 1 10 Forces alarm if number of gate before out of material alarm feeds produce no weight Component 1 Alarm Out of specification Clear gate calibration after out of Spec error Guantity of no material feeds before out of material alarm Setup Component Alarms Basic 4 54 Operation Menus Hopper Setup Batch Hopper The batch hopper setup screens are used to set parameters that are relevant to the batch weigh hopper Parameters include Control Parameters Loading Alarms and Calibration Control This screen sets control parameters which affects the perform ance of the control algorithm Calibrate This screen is used to calibrate the tare weight of the weigh hopper Control Parameters Control parameters that are used to control the algorithm for monitoring the weight in the batch hopper Control This screen sets control parameters which affects the perform ance of the batch weigh hopper The basic alarm parameters are p incl isa A Setting Time ms Setup 2000 0 9999 Time required for hopper to be at rest before dosing Batch Size Setup Based on 0 100 Sets batch size for blender weigh Product Model hopper Oversize Batch Setup 20 0 100 Percent oversize of batch allowed before alarm Minimum Dump Time Setup 2 sec 0 100 Time required to dump blender batch
121. rms processing Home This button is used to return to the main screen of the system Back This button is used to return to the screen previously shown to the current screen e 1S q v A Advanced This button is predominantly used in Setup to access more advanced settings Close This button will close the current screen popup and return to the previous screen Increase Increase the value in the input box or go to the next device Decrease Decrease the value in the input box or go to the pre vious device Page Up Page Screen up Go up to the next screen containing more parameters device data Page Down Page Screen down Go down to the next screen containing more parameters device data Yes Affirmative response to question perform the action No Negative response to question cancel the action Continued Operation 4 9 M enus continued Initial Page When the system is first powered on the touch screen will go through the manufacturer s boot up process Upon completion the TrueBlend SB 2 code will display the Initializing System screen indicating the software 1s loading the configuration of the system setting the initial operating parameters Do not turn off power during the time this page 1s shown In the lower right hand corner of the screen the current Software Version 1s displayed Contact Conair Parts There 1s firmware prote
122. rnal bus power connection is fused The I O power is rated for a maximum of 10 amps however the supply is not The fuse used for the I O power is separate from the buss power The touch screen PP045 is fused with a 5 amp fast acting fuse The X2X network can be extended between remote racks A transmitter module must be used with an associated receiver module The connection can be as far as 100m Each backplane module has a shield connection to its base This is a 0 110 x 0 19 spade terminal Terminate any X2X network cable shield at one end of the cable run and only at one end Within this set of screens the user may view the state of the X20 slices This is shown in the figure below A green status bar at the top of each slice indicates a Good condition A red bar at the top of a slice indicates a Bad condition The user can touch the slice shown on the display to view it in detail After the slice 1s touched the display will show the indi vidual slice parameters Use the buttons to change the slice counter or manually enter the slice number directly Slice numbers are shown on the electrical panel print supplied with the system 4 s20 PLE Diagnostics Continued Operation 4 75 4 76 Operation Menus Diagnostics continuea Slice O is used to identify the data pertinent to the touch screen Slice 1 is the first slice in the system Note Not all slices may be present Additionally there are gaps in th
123. s a maximum of 200 entries Whenever an alarm is activated cleared or acknowledged an entry in this table is created For each entry the following data 1s shown The time of the event State of the alarm The acknowledged status of the alarm The alarm message Continued Operation 4 15 Menus Reports continued Active Alarm Report This report will output the entire list of current active alarms For active alarms only the current state is listed For non current alarms each is updated with the new status Each alarm will remain on the list until the alarm is cleared and acknowledged The time of the event e State of the alarm The acknowledged status of the alarm The alarm message Current Status Report This report prints out the current status of the system First the job name 1f available 1s printed This is followed by the current recipe The recipe values printed match those entered at the recipe screen page In addition to the set values the actual values are printed This is followed by the inventory and shift totals For the shift totals the percentage of the shift totals is also calculated S NOTE This report only prints out the recipe data at the time of the report This report may also be generated as an automated report In this case it is only sent to the printer It is also possible to automatically clear the shift totals after this report is printed The system must be
124. s and resin names can be created and stored The user must have the correct security level in order to edit any values here Changes in the recipe book do not affect the New Recipe or the Current Recipe settings Recipe Book Mame Resin 1 Density Recipe Book Resins Menus Loading Loading Optional The blending system can be configured to perform the pump and receiver sequence for fill ing the component hoppers with resin This is an optional software feature and also requires additional hardware To enable the software portion of this feature go to Setup System and set Loading Enabled to Yes If the option is present the blender PLC will monitor receiver demands and sequence the loaders and vacuum pump to fill the material hoppers Fill times and alarm times for each receiver are also configured in under Loading If an alarm is generated an alarm entry in the master alarm list will also be present Ss ON OFF This button will enable disable loading of this particular receiv er body This information is stored with the system so that in the event of a power cycle the state will return to that before the power failure Loading This is a master on off button for all receiver bodies It will stop all loading immediately Setup This button will take the user directly to the setup page to config ure the load times for the various loader bodies The receiver is requesting a load The re
125. s button is used to set all of the alarm actions back to the factory default state Automatic Setup System Alarms Continued Menus System Setup Alarms continued Enable Email Turns email alarm feature Off or On Level to trigger Service Information General The device that triggers the Alarm Horn Output Shutdown SMTP Address Service Address of SMTP Server IP address of the SMTP server connected to the blender to receive alarm email Port Number Service O None 25 SMTP Server port number Default port number for SMTP servers is 25 Response Timeout Service 60 None 240 Server response timeout Error generated if response from server is not within specified time Use Login Service No Yes No When communicating with the SMTP server does the server Authentication require a user login authentication PLAIN vs LOGIN server authentication If set to YES a username and password must be assigned User Name Service User defined When login authentication is set to YES the login username to the SMTP server Passcode Service User defined When login authentication is set to YES the login password to the SMTP server 4 a z za 4 el En a Receive from Email nable Level to trigger Address mail Output Enable Send to Email Ladres Response Timeout Alarm se Login Authentication Setup System Alarms Email Receive from Email Service No limit Enter the email address Address
126. screens Report Navigate to the report generation screen Language Navigate to the language screen to change display languages ing more parameters device data 0 00 batir Automatic stop Home With Job Mode On 4 12 Operation Continued Menus Home continued Languages The touch screen system supports a variety of languages The default display language is English This can be changed in the setup by either navigating to Setup Panel Language This will change the default display language It is also possible to change the display language without going into Setup This will temporarily change the displayed language until the next reboot or until the user selects a new language To navigate to the Language screen first navigate to the Home page At the Home page press the More button Press the button labeled Language to display the Language screen The Language screen has a button for each language supported Press the button for the desired language The display will now use the selected language Language Tr Spanish E French Language Screen Menus Reports Reports From the Reports screen it is possible to create a variety of reports and output the report to either a USB connected printer or to a USB thumb drive The thumb drive can be on either USB port 1 or 2 and the printer must be plugged into
127. st navigate to the Home page At the Home screen page press the More button Press the button labeled Setup and the screen will change to the main Setup screen Continued Menus System Setup continued System This group of screens is used to set system wide operational parameters Such as system configuration recipe entry format alarm processing network communications and relays Panel This group of screens 1s used to configure the CPU the touch screen units security and system time Diagnostics This group of screens provides diagnostic information and trending information Maintenance This group of screens provides maintenance features including backing up the configuration recipes and resins Defaults This button will reset the system to the factory default settings Quick Setup This button starts an intelligent process where the system can be setup by responding to simple questions e 1S q v A Component This group of screens is for setup of material hoppers and feed systems Batch Hopper This group of screens is for setup of the batch weigh hopper Mixer This group of screens is for setting up the mixer Loading This group of pages is for setting up the receiver bodies and loading times Blower This group of pages is for setting up the loading system blower Continued Operation 4 33 Menus Syst
128. supply and the air supply from the blender Remove existing manual FCV from the rear of the blender Install the automatic version in its place using the original hardware or the new supplied hardware Use removable strength Loctite when installing hardware to make sure that the bolts do not work loose Open the blender door and remove the front plate and mixer from the unit Manually push the slide gate back and then bring it forward to determine where the front of the slide gate ends relative to the opening in the bottom of the mixing cham ber It should just seal off the hole in the mixing chamber there should not be a hole large enough where the material can leak by and it is important that the slide gate does not run past the mixer opening or material binding could occur If this is not correct continue to step 5 Note the FCV is adjusted at the factory and should be adjusted correctly for most blenders If set correctly continue to step 6 Remove the slide gate from the blender remove the cover from the FCV and loosen lock nuts that adjust the length of the assembly as required from step 4 Re install assembly and re check mixing chamber closing Once the length is correct place a small amount of Loctite on the locknuts and re assemble the FCV on the chassis i ee us ER au EEE r Open the control box enclosure door and route supplied tubing through the aoa holes on the right side of the box Remove the existing plu
129. t 00 be ee eee ew 5 3 Software UpgradesS 5 3 Checking Emergency Stop Function 5 4 Changing Material in a Blender Component 5 4 Cleaning Mixing Chamber and Hopper 5 4 gt Draining the Water Separator 5 5 zo Inspecting HOSES aaa aa 5 5 o Removing and Installing the Mixing Chamber 5 6 Calibrating Adjusting the Sensor 5 7 Replacing Pneumatic Cylinder on Vertical Dispense MAING egus dias aa 5 9 Load Cell Removal and Installation 5 10 Weigh Bin Mount Installation and Adjustment 5 11 Load Cell REMOVd c nek kone ue Bana dae cs 5 14 Load Cell Installation eae aa e baw ee we eS 5 15 Maintenance 5 1 Preventative Maintenance Schedule The TrueBlend SB 2 system contains components that should be verified for proper opera tion every six months The integrity of the TrueBlend SB 2 Batch hopper load cell is important for reliable and accurate control of the system See the Operation section enti tled Menus Hopper Setup Calibration of Batch Hopper for more information Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the Blender We recommend the following maintenance schedule and tasks e Whenever you change materials O Check EMERGENCY STOP function O Test the safety interlock switch O Clean the extruder weigh hopper s e Monthly or as often as needed
130. t materials can be metered and mixed in the blender depending on model The following must not be metered and mixed e Foods of all types unit does not meet hygienic standards e Highly abrasive materials such as stones sand increased wear of unit components e Poorly free flowing sticky materials airtight seal by the pneumatic cylinder is adversely affected e Liquids and powders airtight seal by the pneumatic cylinder is not possible Included Safety Features N Safety Interlock Switch The access door is equipped with a safety interlock switch that prevents the mix motor from running and the slide valves from operating Do NOT defeat this safety switch N Hopper Finger Guards Finger guards are fitted into each hopper compartment Do NOT reach through these guards Do NOT use your fingers to clear an obstruction below these guards Do NOT remove these guards 1 4 Introduction How to Use the Lockout Device MN CAUTION Before performing maintenance or repairs on this product you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start up A lockable device has been provided to isolate this prod uct from potentially hazardous electricity Lockout is the preferred method of isolating machines or equipment from energy sources Your Conair product is equipped with the lockout device pictured below To use the lockout device 1 Stop or turn off the equipment 2 Iso
131. t to make a new batch once mixer dumps out Batch rate update count Service 3 Number of times to make a batch to aver age and display lbs hr or kg hr on Home page Maximum percentage the batch weight is allowed to rise when at rest before a Gate Valve Failure alarm occurs Leak detection percentage Service Leak detection time Service 3 seconds Maximum seconds the batch weight is allowed to rise when at rest before a Gate Valve Failure alarm occurs Control Enable High Temperature Mode Batch Rate Update Count Leak Detection Percentage Leak Detection Time Setup Batch Hopper Control Advanced Continued Operation 4 57 Menus Hopper Setup continuea Calibration Calibration is the process by which the tare weight of the hopper is determined In order to determine the weight of material in the hopper two weight readings are required an empty hopper weight and a hopper weight with some known weight present The True Blend sys tem uses a Manual Calibration procedure to learn the tare weight of the hopper After the tare weight is learned the maximum hopper weight is obtained by placing a test weight in the hopper D Note The blender must be stopped and the user must have a security level of Service Calibrate This screen is used to calibrate the tare weight of the weigh hopper Manual Calibrate Press to Calibrate the weigh hopper 7 using a test weight Follow instr
132. th full color graphics allows quick and easy set up User friendly screens are configurable to match each specific injection or extrusion process Simple menu driven touch screens ask all appropriate questions for ease of indi vidual application set up The operator enters the blend recipe here The operator can also monitor the blender control set points current and past alarm status and complete management of material inventory data Recipe Entry Modes Depending upon the control mode selected there are several recipes entry options The available recipe entry options determine how an operator would enter that data needed to control the blender Simple menu driven touch screens ask all appropriate questions for ease of product recipe set up The recipe entry options available are configured from the Setup screen From the Home Screen press More Setup System Recipe From this screen you select whether your recipe is an Injection format allows Naturals Regrinds Additive Naturals and Additive Batch recipe entry or Extrusion format allows Natural and Regrind recipe entry Resin and Product Names Resin names are used to identify the various resins included in the products There can be up to 250 different resin names entered and each name can be comprised of a 10 character alphanumeric name The TrueBlend SB 2 controller will keep inventory totals for each resin name defined Product names are used to identify the various producti
133. the enclosed packing list Make sure all parts listed are present and that no visi ble damage exists Inspect all of the equipment in the presence of the freight carrier s representative for dam age during shipment Note any damage on the delivery receipt before signing it If damage is evident file a claim immediately against the carrier as it is their responsibility to pay for any damage incurred during shipping Make sure to include a detailed report of the damage along with photos The TrueBlend SB 2 blender arrives wrapped on a skid The packaging could include depends on the options selected e HMI operator panel e Control cable to connect the control to the electrical cabinet e Weigh bin e Slide gate option e User manual and wiring diagrams not shown 1 Carefully unwrap the blender and components on the skid 2 Remove all packing material protective paper tape and plastic IMPORTANT Do NOT use excessive force Forces that are exerted on the load cell from outside when attaching and removing the weigh bin load cell may damage the very sensitive load cell 3 Carefully remove the mixing chamber Use the instructions on the sticker located inside the door of the blender chassis to remove the mixing chamber 4 Unbolt the blender from the skid 5 Using the lifting lug provided lift the unit off of the skid IMPORTANT Do NOT lift the blender except by using the lifting lug provided If the weight is uneven
134. the setup security level Service Password Service 1111 The passcode needed to enter the serv ice security level Auto Logout Service The amount of time that passes in sec Timeout onds before the current security level is changed to the minimum security level Guest O disables 300 or higher valid o Panel Security Operator Password Setup Password Service Password Auto Logout Timeout Setup Panel Security Advanced 4 50 Operation Continued Menus System Setup Security continued Date This screen sets parameters relevant to the current system time Date Set the current system time and date The basic parameters are Hour Setup 0 24 Using a 24 hour clock this value represents the current hour Minute Set the current minute ee Set the current year using a four digit value Setup Panel Date Basic Clear Shift Totals Service No Yes Clear the shift totals after a Shift Report is After Report No completed Enable Service Check or Enables Shift 1 2 or 3 Automatic Shift Reporting None Outputs Name Service Shift 1 2 or Enter the desired name of the shift 3 Start time Service Hours Enter the start time of the shift Minutes Duration Service Hours Enter the time length of the shift Minutes Operation 4 51 4 52 Operation Menus Component Setup continued Clear Shift Totals After Report Start Time Duration HH witi HH hitt Enable
135. the water separa tor 1 and drain the water 2 Tighten the knurled screw ile 0 ER 3 Check that all screws attachments and connections are firmly attached Inspecting Hoses Loose or damaged hoses can allow moisture regain or material contamination Compressed air leaks are also expensive and wasteful 1 Inspect all hoses clamps fittings 2 Tighten any loose hose clamps or fittings 3 Replace worn or damaged hoses J a q 0l a ap q Maintenance 5 5 5 6 Maintenance Removing and Installing the Mixing Chamber 1 Turn all 1 4 turn fasteners on the front panel counter clockwise until they release Remove the front panel Some models require lifting the panel to clear 2 screws at the bottom Remove the mixing agitator by pulling straight out You may need to rotate the shaft as you remove it in order to clear the front bin wall Lift the front of the mixing chamber to align the locking pins with the release slots Pull the mixing chamber forward until release extension on the bottom of the chamber interfaces with the nylon drain port Place hands under chamber and lift fingers to raise the back of the bin over the drain port Pull bin straight out Align bin walls with guides and push straight inward until the extension on the bottom of the chamber interferes with the nylon drain port Place hands under chamber and lift fingers to raise the back of the bin
136. ting occurs If this bolt was not loos ened during removal or installation it should not need adjusted If it was loosened the gap needs to be reset so the load cell contacts the bolt when the weigh bin is loaded with 3kg total weight A 040 feeler gage could be used to set the gap 5 10 Maintenance Load Cell Removal and Installation Models TB045 TB100 WARNING Electric Shock High voltages can cause life threatening currents in the body and injury from elec tric shock Allow only trained and qualified electrical technicians to work on the electrical system Before any electrical work disconnect the unit from the power supply and lock to prevent unauthorized persons switching it on Do NOT use excessive force Forces that are exerted on the load cell from outside when attaching and removing the weigh bin load cell may damage the very sensi tive load cell Remove the weigh bin Disconnect the wiring that extends into the control box see wiring diagram Remove the two screws 2 that are used to mount the load cell and weigh bin mounting bracket to the load cell mounting bracket 7 Hold the load cell in a vise or similar and remove the two screws 3 from the load cell Mount the weigh bin mounting bracket 1 onto the new load cell using the two screws 3 and tighten to 10Nm Make sure that the weigh bin mounting bracket 1 is perpendicular and square with the load cell Place a small amount
137. ting the blender on a stand surge bin or hopper TB900 4 hopper positions three and four are supplied with 12 8 adapters with eight inch cover plates as standard TB900 6 hopper positions three and six are supplied with 12 8 adapters and eight inch cover plates as standard Numbers in top view drawings represent hopper positions Specifications may change without notice consult with a Conair repre sentative for the most current information Description TPBX031 091 1 SPECIFICATIONS Side view E gt NOTE Side and front view drawings are shown for model TB1800 6 The bin positions change for a TB1800 4 and TB1800 5 models see the top view Performance characteristics Batch size lbs g grams or kilograms Maximum throughput lbs hr kg hr Bin capacity main ingredient ft liter 6 170 Bin capacity minor ingredient ft liter 6 170 Maximum number of materials 4 Number of major valves 4 5X5 Number of minor valves 0 Dimensions inches mm Height above mounting plate Hopper width and depth square Overall depth Controller height Controller width Controller depth Loader center distance 30 00 762 0 Loader center distance 30 00 762 0 Loader center distance N A Loader center distance A Loader center distance Weight lbs ko Shipping o Voltage total amps 220V 1 phase 50 hz 220V 1 phase 60 hz 240V 3 phase 60 hz 400V 3 phase 50 hz 480V 3 phase 60 hz 575V 3 phase 60 hz Compress
138. tion section entitled Menus Manual Control to see how to run the mixer manually 6 If applicable open the discharge slide gate at the bottom of the mix cham ber 7 Open the mix chamber access door The safety switch will prevent operation of the mixer with the door open e Tip If using the optional drain chute with safety interlock open the front access door remove the weigh bin and position the chute to direct material into a bucket or drum rather than the mix chamber 4 80 Operation Continued Cleaning the MIXer continuea 8 In the Home screen press More Setup Maintenance Manual EM Manual Control Control T pa 9 Press on the appropriate valve icon to open the selected valve gate Removing material The dispense valve unit is opened and the material runs out of the material hopper through the optional deflector to the col lection receptacle 1 Discharge the material completely and clean the material hopper from the top 2 Press on the appropriate material hopper icon again to close the dosing unit 3 Remove the optional drain chute If equipped Now follow the steps outlined in the Operation section entitled Cleaning the Mixer to access and clean the mix chamber and the bottom discharge valve Operation 4 81 4 82 Operation SECTION Maintenance Preventative Maintenance Schedule 5 2 Preventative Maintenance Checklist 9 2 Loading Equipmen
139. tomatic button to start the blending process automatically with the new Set recipe values and Options See the Operation section entitled Menus Recipes for more detailed information Stopping the Blending Process 1 Press the button Stop to stop the metering and mixing process The current batch will run until it is finished unless the operator chooses the button to stop immediately When finished the Automatic display changes to Stop Security Settings Security levels dictate what data is accessible by the user On each screen page in the upper left corner a numeric box indicates the current level of security The security number level color and default passcodes are as follows 0 Green Guest minimum security level e 1 Yellow Operator Passcode 3333 e 2 Orange Setup Passcode 2222 e 3 Red Service maximum security level Passcode 1111 The passcodes for each level can be changed in the Setup Panel Security screen Refer to the Operation section entitled Menus Security for more information regarding user defined passcodes and setting up the security system Operation 4 3 4 4 Operation Menus Licensing The software on the Compact Flash CF card requires a license in order to boot the system to the Home page The license is generated from the Station Identifier of the touch screen unit Removing the CF card and installi
140. try Menus Alarms Alarms The TrueBlend SB 2 system contains alarms for each device in the system There are three levels of alarm severity Information General and Shutdown A single alarm may have a different severity level based on which operating state the system is in For example an empty hopper alarm may be a General alarm when the system is stopped but it is a Shutdown alarm if the system is running Each alarm type and the severity assigned can be viewed and edited in setup To navigate to the Alarms Setup section from the Home screen press More Setup System Alarms The last 100 alarms are logged to the system and even after a reboot sequence are available for viewing This log can be cleared by the user The logged alarm list has additional entries indicating when the alarm became inactive as well as when each alarm was acknowledged The active alarm list can be reached by pressing the Alarm button on any screen of the system The Alarm button is color coded to reflect the worst severity active alarm Alarm severity color codes are as follows Information Alarm Green This alarm severity indicates a non critical condition which should soon be resolved General Alarm Yellow This alarm severity indicates a serious condition that needs immediate attention Shutdown Alarm This alarm severity indicates a critical condition amp caused the line to shut down requires immed
141. uctions on screen Calibrate EEE oh bone ens sia Y I L LARA te Setup Batch Hopper Calibrate 4 58 Operation Menus Mixer Setup Mixer Setup The mixer setup screens are used to set parameters that are relevant to the mixing device Parameters include Control Parameters Control Parameters Control parameters that are used to control the algorithm for mixing the material and con trolling the mixing chambers dump gate Control This screen sets control parameters which affect the perform ance of the mixer a SS INDI Maximum Dump Time Setup 5 0 60 Open seconds for mixer dump valve Mixer Idle Time Setup 30 0 9999 Idle time for mixer if batch not dumped after mixing Idle Mix Time Setup 3 0 60 Mix time for mixer if batch not dumped after mixing Material Request Source Setup Mixer Sensor Mixer Prox External Input Extruder Hopper TBEXT Only Remote Hopper TBEXT Only Operation 4 59 4 60 Operation Menus Loading Setup JE Control Setup Mixer Control Basic Loading Setup The blender has the capability to provide self loading It will monitor requests for loads from the receiver bodies and then sequence the receiver valves and the blower pump to load material This feature requires an unlock License code Once unlocked the setup page will provide two additional setup buttons in the command bar for setting up both the loaders and the blower pump Menus Loader Setup Loader
142. uide paying particular attention to hazard warnings appendices and related diagrams Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment e Step by step adherence to instructions outlined in this User Guide ATTENTION Read This So No One Gets Hurt We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide N WARNING Improper installation operation or servic ing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical personnel who are familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by qualified electrical techni cians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate N WARNING Voltage hazard This equipment is powered by single phase alternating current as specified on the machine serial tag and data plate A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical
143. up parameters that affect the action an alarm takes in the vari ous system operating states Stop Manual and Automatic The steps to customize an alarm are 1 Alarms are assigned to devices Examples of devices are extruders additives a haul off and the CPU System computer Once a device has been selected the available alarms for that device will be listed in the alarm pull down menu 2 Select the alarm assigned to the device 3 The alarm actions for the selected device and alarm are displayed an action for each of the system operating states Use the pull down menu to select the desired action Continued Operation 4 37 4 38 Operation Menus System Setup Alarms continued Parameter Securiy Defaut Description Level To Service Information General The alarm severity action which energizes Trigger Output Shutdown the alarm relay contact Device Service System Mixer batch The device that triggers the Alarm Level Hopper Component X Alarm Service Various Alarm name Various The alarm name depends upon the that appears on the Device Chosen Screen Stop Service None Information Alarm Name Priority Level when blender is General Shutdown stopped Automatic Service None Information Alarm Name Priority Level when blender is in General Shutdown Automatic Email Service Alarms sent to emails Configures SMTP server to allow email alarm notifications Defaults The default
144. upply in order to discharge any electrostatic charge Contact Conair Parts from your body 1 800 458 1960 From outside of the United States call 814 437 6861 p 2 Remove the battery cover from the top of the Power Panel device using a screw driver 3 Pull the plastic tab to remove the battery 4 Make sure the new battery is correctly aligned see symbol on the battery sock et and the plastic strip is around the battery so it can be removed in the future 5 Replace cover 6 10 Troubleshooting Replacing Load Cells 1 2 Remove the material from the TrueBlend SB 2 extruder hopper Disconnect the load cell wiring that extends into the control box see wiring dia gram Remove the two screws that are used to mount the TrueBlend SB 2 extruder hopper to the load cell Remove the TrueBlend SB 2 extruder hopper Remove the two screws that are used to mount the load cell to the hopper frame Place a small amount of removable strength Loc tite onto the two screws and re install the load cell and TrueBlend SB 2 extruder hopper back onto the hop per frame Make sure that the load cell and hopper are mounted square with the hopper opening exit and tighten the screws to a value of 10 Nm Do NOT use excessive force Forces that are exerted on the load cell from outside when attaching and removing the TrueBlend SB 2 extruder hopper load cell may damage the very sensitive load cell ES NOTE A set screw position
145. ve Maintenance CheckliSt oooooooomooo 5 2 Loading Equipment n a G0 actt diem de Sim dat dies bck lheat delisted dient ea ated 5 3 Software Upgrades socorrer 5 3 Checking Emergency Stop Function anaana aeaea 5 4 Testing the Safety Interlock Switch o ooooooommoo o 5 4 Cleaning Mixing Chamber and Hopper 0 00 cee eee eee ee 5 4 Draining the Water Separator 0 0 0 0 ccc eee eee eee eee 5 5 inspecting HOSES gt repasa cane cee ape pep ape pee peoples 5 5 Removing and Installing the Mixing Chamber 5 6 Calibrating Adjusting the Sensor 0 0 0 0 ccc cece eee ees 5 7 Replacing Pneumatic Cylinder on Vertical Dispense Valve 5 9 Load Cell Removal and Installation cscrsicevecreewserseweeneune wes 5 10 Weigh Bin Mount Installation and Adjustment 5 11 Load Cell Removal ca renr ache eens rea 5 13 Load Cell NSIDC PPPPAPApPO5 O0O0PC7 D E p 5 14 Table of Contents iii iv Table of Contents 6 1 Troubleshooting continued Before Beginning 0 0 c cece eee eee eee eee eee eee eens 6 2 A Few Words of Caution 0 ccc ccc teen nes 6 2 DIAGNOSTICS How to Identify the Cause of a Problem o oo 6 3 Signaling Alarm Message ici eae ee ce ee ee 6 3 Handling Alarm Messages 0000 cece eee eee eee teens 6 3 AGUS cc enue eee eee Ina 6 4 REPAIR Replacing Fuses
146. vement The lockout procedure must include all energy sources Electrical power supply Compressed air supply Hydraulic fluids under pressure Potential energy from suspended parts Energy in springs Any other source that might cause unexpected mechanical movement The following is a recommended Zero Mechanical State procedure which must be followed prior to any inspection adjustment or maintenance of the system 1 If there is a remote control device press the lt STOP gt key at that remote operator s control 2 Press the lt STOP gt key at the local TrueBlend SB 2 control panel 3 Disconnect and lock out the primary electrical supply feeding the TrueBlend SB 2 controller 4 Disconnect and lock out the primary electrical supply feeding the material handling system that is feeding the TrueBlend SB 2 material hoppers with process material 5 Shut off and lock out the primary compressed air supply that is feeding the material handling devices Vent the compressed air supply lines 6 On each TrueBlend SB2 disconnect all of the cables leading to the motor of the metering device Where applicable 7 Drain any process material from the loading devices feeding the TrueBlend SB 2 material hoppers 8 Lock out all energy sources which might cause unexpected movement of equip ment which is accessible through the discharge at the base of the TrueBlend SB 2 extruder hopper 9 Test to verify that all energy sources have actually be
147. y Pump Service 13 0 255 The PLC Slot address of the Starter Slot networked blower not yet supported Secondary Pump Service 1 Starter Output Channel Number on the Starter Channel Slot Setup Blower Advanced Operation 4 63 4 64 Operation Menus Diagnostics Diagnostics The diagnostics screens are used for diagnosing system control Main Diagnostics Page From the main Setup page press the diagnostics button to see the main diagnostics page Trending Navigate to a trend screen to select from a variety of data values These values are plotted versus time The user can display or manipulate the plots X20 PLC Navigate to screens that display the status of the X20 PLC slices slots and the i o within the system Batch Hopper Navigate to screens that display the status of the current batch being processed by the batch hopper Component Navigate to screens that display the status of the selected gate as well as screens which can perform feed by time and weight tests Simulation Navigate to a set of screens where the various devices in the system can be put into simulation mode Diagnostic fal Diagnostics main Menus Maintenance Maintenance The maintenance screen buttons allow saving and retrieval of the configuration recipe and resin names to a USB thumb drive This screen also displays the license pass codes for the remote communication option s purchased with the system

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