Sterling 100 - Manual

Continuous Loss-in-Weight Blenders Chapter 1: Safety 7 Continuous Loss-in-Weight Blender Safety Tags Tag Description Tag Description Pinch Point - Slide Gate Read Operation & Installation Manual Shear Point - Rotating Mixer or Agitator Earth Ground High Voltage Inside Enclosure PE Protected Eart...

Continuous Loss-in-Weight Blenders Chapter 1: Safety 8 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following pertinent local and national codes. This may include, but is not limited to OSHA, N...

Continuous Loss-in-Weight Blenders Chapter 1: Safety 10 Operator Responsibility The operator’s responsibility does not end with efficient production. The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations. Plant and personnel safety i...

Continuous Loss-in-Weight Blenders Chapter 1: Safety 11 • Clean the blender and surrounding area DAILY , and inspect the machine for loose, missing or broken parts. • Shut off power to the blender when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Mainten...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 12 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for continuous loss-in-weight blenders of various blending rates and specifications. ...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 13 2-3 Typical Features & Components Mechanical Features • Blender automatically adjusts individual feeders to match learned extruder rate at the ratio required. • Upper material supply hoppers with conical re-fill valves and d...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 14 Blender System Component Description This section describes the various components of the continuous blending system. The continuous blending system is made up of the following components (See Figure 2 below): • Ingredient suppl...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 15 hoppers are not controlled nor read by the blender. Their existence is solely for the use of a low level alarm to be wired into a separate controller. These would not be present on a standard blender. The hoppers may be equipped...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 17 Lower Mass Flow Weigh Hopper Assembly The lower mass flow weigh hopper, otherwise known as the weighed common hopper, is used to determine the actual processing rate of the processing machine so that the blender can be slaved in...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 19 2-4 Options The following is a list of options, which your blender may have been equipped with: • Mezzanine stand with slide gate and 4” tube stub. • Low-level proximity switches. Detects material supply shortages for each suppl...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 20 2-5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the continuous loss-in-weight blender. This manual is not intended to supersede or alter safety standards ...

Continuous Loss-in-Weight Blenders Chapter 2: Functional Description 21 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. The safety devices that are used on the continuous loss-in-weight blenders are primarily concerned with electrical power disconnection and ...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 22 Chapter 3: Installation 3-1 Uncrating the Equipment Continuous loss-in-weight blenders are shipped bolted on a skid, enclosed in plastic wrap, and contained in a wood crate. 1. Remove the crate from around blender. 2. Secure strap of prop...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 23 Site Requirements This section describes site requirements in detail. These requirements are broken down into mechanical mounting, electrical connections and pneumatic connections. Since the continuous loss-in-weight blender is available ...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 24 Note: Never weld on the blender’s frame, machine or mezzanine without first removing the control panel and verifying that the blender’s power is disconnected. Mezzanine Mount In a mezzanine mount application, review the following items be...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 25 Note: Ensure that the feed tube angle is steep enough (60 degrees is recommended). Note: Some mezzanine mount applications will require the blending system’s lower mass flow hopper be mounted on the extruder throat. The metering section w...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 26 Figure 8: Typical Layout for a floor mounted blender 3-3 Electrical Installation The continuous loss-in-weight blending system is designed to operate on 115 volt, single phase, 50 or 60 hertz AC power. The power requirements will vary wit...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 27 3-4 Pneumatic Installation The blending system utilizes air pneumatics to perform the re-fill function on the ingredient weigh hoppers. The manufacturer provides all pneumatic plumbing to a single ¼” standard pipe thread fitting. The blen...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 28 3-5 Overall Installation (Summary) This installation procedure should be used as a general guideline for the proper installation steps required to install the continuous loss-in-weight blending system. 1. Visually inspect the extruder or ...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 29 3-6 Set-up This section will discuss the mechanical setup and control system setup of the continuous loss-in-weight blending system. After reading this section, you should be familiar with the mechanical setup and the electronic control s...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 32 will suffice. The weight will be in pounds, unless the blender is provided for metric display operation (kilograms). Given the two weight points on the load cell scale, the controller will be able to determine any other weight on the load...

Continuous Loss-in-Weight Blenders Chapter 3: Installation 34 Touch “Scale” button Find your calibration weight that shipped with the blender and locate the Weight information stamped on the weight proceed as follows. 1. Enter weight value stamped on the weight in Cal Wt Box . 2. Make sure weigh hop...

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

Continuous Loss-in-Weight Blenders Chapter 3: Installation 38 Touch “ Hopper Setup” Touch the box next to the hopper number that you want to change and enter weight value. Setting Passwords There are three levels of password security for the control system. - User (factory set to “5413”) - Service -...

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

Continuous Loss-in-Weight Blenders Chapter 3: Installation 40 -Enter original password. -Touch box next to select operator until you see the level you want to set. (operator, service) -Touch New Password and enter your new password -Touch Verify Password and verify you new password Alarm Setup There...

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

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

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

Continuous Loss-in-Weight Blenders Chapter 4: Operation 47 Chapter 4: Operation 4-1 Start-up The objective of this chapter is to familiarize the reader with the blender’s recipe menu, run mode operation and displays. Upon completion of this chapter, the reader will be familiar with the recipe and ru...

Continuous Loss-in-Weight Blenders Chapter 4: Operation 48 The blender will blend at a maximum rate when the lower mass flow weigh hopper has a very low weight of material. As the weight of material increases in the mass flow weigh hopper, the controller will adjust the blender feeders output to mat...

Continuous Loss-in-Weight Blenders Chapter 4: Operation 49 4-2 Controller Description & Operation Display Description The controller on the continuous loss-in-weight blender, utilizes a LCD touch screen display. Figure 14: Typical Controller Display A typical menu entry is shown in the figure ab...

Continuous Loss-in-Weight Blenders Chapter 4: Operation 50 “Inventory” page ¾ Clear Inventory ¾ “Next” returns to “Recipe” page “Setup” Page ¾ Touch the ACS icon and enter in the “user password” Hopper Setup ¾ Hopper size “Recipe” Page (Start) ¾ Extruder RPM is displayed ¾ Extruder throughput is dis...

Continuous Loss-in-Weight Blenders Chapter 5: Maintenance 52 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of the blender is simple and little maintenance is required. The only moving parts are the re-fill valves, optional regrind agitators, metering augers, and ...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 54 Chapter 6: Appendix 6-1 Spare Parts Typical Blender Parts List # DESCRIPTION 015 060 100 Lid (0.2 to 1.6 cu. ft. vacuum receivers) 08223-1 08278A 08412-1 1 Lid (3.0 and 6.0 cu. ft. vacuum receivers) N/A N/A A0770325 2 1/8” NPT fitting 35085K ...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 55 Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius (104 degrees Fahrenheit) – Ma...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 56 6-2 Addendum (Service Supervisor Information) Caution! After all selections are made: Keep pressing the “Done” key until the unit returns to the Recipe menu. Passwords • User Password “5413” • Maintenance Password “3145348” Caution! Maintenan...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 57 Once you access the Engineering Menu you will see the following. This is where you make adjustments to fine tune the blender’s performance. You will need to assess the FIFO page previously mentioned in the manually to decide what changes need...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 58 Feed Factor Filter This filter allows you to set the number of snapshots that the FIFO page looks at to find the average deviation. Making this number bigger will cause the feeder to make changes slowly, and decreasing the number will make ch...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 59 Advance PID Options (mass flow setup) Sample Time once in Steady Window for FIFO This is how often the control takes snap shots of the mass flow hopper and enters the number in the FIFO table. For quicker FIFO updates you would decrease this ...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 60 PID Integral Constant Works the same as the Gain. Feeder Speed Limits This allows you to set the minimum and maximum speed for the motor drives as a percentage. The drives are not supposed to be run at less than 8 hertz and should not be run ...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 61 Allowed Extruder RPM Change for Steady Flag This is how much the extruder RPM can vary and still be considered steady. With no extruder measurement the control always assumes a steady RPM. Update Time for Prox Method in seconds This is how of...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 62 Advanced Alarm Options This alarm is for no material flow through a auger, this could be caused by a blockage stopped motor etc. No Flow Timer This is the amount of time used to measure the bit flow (weight loss) through a hopper, to determin...

Continuous Loss-in-Weight Blenders Chapter 6: Appendix 63 6-3 Technical Assistance Parts Department Call toll-free 7 am–5 pm CST 800.423.3183 or call 262.641.8610 Fax 262.641.8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering desi...