Sterling A0567659 7 Troubleshooting

SGB Batch Blender with Mitsubishi Controller Page 85 of 118

7 Troubleshooting

7-1 Description and Objectives

This section provides basic troubleshooting procedures to common SGB blending

system problems. Any problem encountered that is not listed should be discussed

with an Sterling service technician.

Problem Possible solution

Check to make sure that air is hooked up and the regulator gauge reads

at precisely 60 PSI.

Check that the access door to the mixer is shut properly.

Nothing happens when I

push “Start Blender”

Look on the Recipe Screen. If you see “Mixer Full”, then check the mixer.

If the mixer is not full, then check that the mixer prox is adjusted properly

(small screw on back).

“E-STOP has been

Activated” is shown

Check the E-Stop located on the front of the blender panel.

“Interface has been

Locked” is shown

Click “Unlock” and enter in your User Password.

I’ve forgotten my User

Password

Contact Sterling’s Service Department.

POWER INTERRUPTION

ALARM

Power was lost during a batch. Check your power source unless you

intentionally killed the power during the batch.

PLC Battery Low Change out the PLC battery with your spare

Check the input power. Verify that 110 volts (or 220 volts) are ±10%. This

voltage must remain constant with all the motors starting and stopping.

Insure that the blender is on a “clean” circuit that does not have other

equipment on it. If the power is known to be intermittent and have

problems, set up the unit to run in “AutoStart” mode. See the factory

setup sheet at the end of this manual. In this mode, if a short power

interruption occurs, the blender will automatically restart.

Check the power supply. Make sure that it has +5 VDC output to the CPU

board. Adjust to +5 VDC, ±0.1 volt.

Check the display ribbon cable connection to the CPU board and the

display. See the electrical chapter for more information.

Check the contrast adjustment located on the display board.

Check keyboard ribbon cable connections.

PLC Module Loaded

Check the CPU board for “lockup”. To do so, reset the CPU board by

cycling the power off and on at the motor control panel.

Contents

Main Page Table of Contents Page Safety Considerations Page Annex B Information 1 General Information 1-1 Introduction 1-2 Equipment Function 1-3 Accessories 1-4 Customer Service 1-5 Necessary Documents 1-6 System Capabilities 1-7 Equipment Covered by this Manual SGB Blenders SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 1-8 SGB Series Weigh Blender Mechanical Features SGB Slide Gate Blender 1-9 SGB Series Weigh Blender with Mitsubishi Touch- Screen Control Features 1-10 SGB (-E) Series Specifications Note: SGB features and specifications are subject to change without notice. 1-11 Model SGB Blender System Component Description 1-11-1 Material Supply Hoppers Typical Material Supply Hoppers 1-11-2 Slide Gate Metering Assemblies Important! Slide gates create a pinch-point hazard. Important! 1-11-3 Weigh Hopper Important! Use care when replacing the weigh hopper, since the load cells are 1-11-4 Weigh Hopper Discharge Valve CAUTION! The pneumatic system used on the SGB, like all pneumatic 1-11-5 Mix Chamber 1-11-5-1 Opti-Mixer 1-11-5-2 HC Mixer Page Typical Operator Screens Note: than shown. 1-12 Pneumatic Slide Gate Below Mixer (Optional) TYPICAL CENTRAL BLENDER LAYOUT Safety 2 2-1 Work Rules 2-2 Tools and Equipment Needed 2-3 Mechanical Installation 2-4 Safety Considerations REPORTING A SAFETY DEFECT 2-5 General Responsibility NO MATTER WHO YOU ARE 2-6 Operator Responsibility 2-7 Maintenance Responsibility 2-8 Safety 2-8-1 Description and Objectives 2-8-2 Safety Circuit Standards 2-8-3 Fail Safe Operation 2-8-4 Safety Device Lock-Outs WARNING! Alw ays disconnect and lockout all electrical power and pneumatic 2-8-5 Lock-Outs, Plugs, and Other Safety Devices WARNING! 2-9 Electric Safety Interlock Switch (All Models) WARNING! Always disconnect and lockout all electrical power and pneumatic 3 Shipping Information 3-1 Unpacking and Inspection 3-2 In the Event of Shipping Damages Important! Parcel Post Shipment United Parcel Service Shipment 3-3 If the Shipment is Not Complete 3-4 If the Shipment is Not Correct 3-5 Returns Important! - Notes - Installation & Setup 4 4-1 Chapter Description and Objectives 4-2 Site Requirements 4-2-1 Mounting Configuration 4-2-1-1 Machine Mount Note: Allow at least 36 clearance around blender to provide 4-2-1-2 Mezzanine Mount Important! While in operation, the SGB applies horizontal and vertical 4-2-1-3 Floor Mount (Central Blender) Important! TYPICAL CENTRAL BLENDER LAYOUT 4-3 Installation Overview 4-4 Mechanical Installation CAUTION! Important! 4-5 Electrical Installation 4-6 Pneumatic Installation Important! As this blender uses air for blender metering functions, it is CAUTION! 4-7 Blender Set-up 4-7-1 Description and Objectives .040" GAP STOP ADJUSTMENT BOLT 4-7-4 Final Setup Important! Again, make sure that proper air supply connections are made to Page Operation 5 5-1 SGB Blender Sequence of Operation 5-2 Quick Start Procedure 5-3 Recipe Entry Formats 5-3-1 Quick Set Important! 5-3-2 Percentage Mode Important! 5-3-3 Parts Mode Page 5-4 SGB Series Control System Menu Structure Recipe Book Page Clean Out Page Return to the Recipe Page Inventory Page Return to the Recipe Page 5-5 Blender Calibration 5-5-3 Additional settings that usually do not have to be changed: Page 5-5-4 Verifying Calibration (Recommended on a periodic basis to ensure accuracy) 5-6 Controller Mode Setup Setting up a recipe Page 5-7 Color Change Note: The blender must be stopped to make color changes. The processing WARNING! Important! WARNING! 5-8 Additional Operation Features 5-8-1 Display Description (LCD) 5-8-2 Weigh Hopper (Load Cell) Calibration on blenders equipped with an OptiMix mixer 5-8-3 Mix Timer 5-8-4 Re-Mix Timer 5-8-5 Mixer Options 5-8-6 Weigh Hopper Dump Time 5-8-7 Weigh Hopper Dump Delay Time 5-8-8 Weigh Hopper Dump Cycle 5-8-9 Feeder Alarm Setup & Flags Page Page 5-8-10 Additional Control Functions 5-8-11 General Operation 5-8-12 Feeder Clean Out Important! 5-8-13 Standard Run Time Displays Note: 5-8-14 Recipe Menu Note: 5-8-15 Current Recipe Menu Note: 5-8-16 Quick Set Menu Page Example calculations of a five (5) -component blend in Quick Set 5-8-17 Batch Size Menu Important! If running a high percentage of lighter density regrind. 5-8-18 Inventory Shutdown 5-8-19 Recipe Book (Storage) Menus 5-8-19-1 Save Running Recipe to the Book 5-8-19-2 Load a Saved Recipe from the Book Note: If replacing the current recipe with one that is downloaded 5-8-19-3 Display Recipe Contents 5-8-19-4 Erase Recipe or Entire Book 5-8-20 Controller Features 5-8-20-1 Display Time and Date 5-8-20-2 Setting Date & Time 5-9 Stroke Limiters for Metering Gates Maintenance 6 6-1 Work Rules 6-2 Maintaining Blenders WARNING! 6-3 Controller Setup 6-4 SGB Series Blender Menu Structure 6-5 Mechanical Typical Model SGB Assembly Overview 6-6 Electrical 6-6-1 Description and Objectives 6-6-2 Internal Components of the Control Panel Note: See Section 12-2 for complete electrical schematics. 6-6-3 Input Signals to Programmable Controller Note: 6-7 Pneumatic System Maintenance Important! WARNING! 7 Troubleshooting 7-1 Description and Objectives Page Page Other service problems or questions can be answered by contacting the Sterling Service Department. 8 Blender Options Spare Parts 9 9-1 Spare Parts List SGB Series Gravimetric Batch Blending Systems 9 Please see Section 9-2 for parts identification and exploded views. Model SGB-450 9-2 Model SGB Blender System Component Description 9-2-1 Overview Component Identification and Location Typical Model SGB Assembly Overview Page 9-2-3 Typical Mixer Section (Rear) Typical Opti-Mixer - Rear Assembly Detail 9-2-4 Typical Mixer Frame Typical Opti-Mixer Frame Assembly 9-2-5 Typical Gate Assembly Typical SGB Series Diamond Gate Assembly Detail 9-2-6 Typical Supply Hopper Typical SGB-450 Series Hopper Assembly Detail 9-2-7 Typical Weigh Hopper Typical Weigh Hopper & Load Cell Detail Technical Assistance 10-2 Returned Material Policy 10-2-1 Credit Returns 10-2-2 Warranty Returns 10-3 Warranty Safety Tag Information 11 11-1 SGB Blender Safety Tags 11-2 Pushbutton and Touchscreen Tags Button Function Power Off Page 12 Appendix Important! 12-1 Addendum Service Supervisor Information 12-1-1 Programmable Settings 12-1-2 Factory Setup Menu Page Page 12-1-3 Customer Setup Menu Important! Programmable features should not be accessed by Page 12-2 Passwords 12-3 Default Values (factory defaults shown): SGB BLENDER CONFIGURATION PARAMETERS RECIPE FORMAT SGB BLENDER CONFIGURATION PARAMETERS Contd. ALARM SETUP ADVANCED WEIGHT OPTIONS FEED ALGORITHM OPTIONS SGB BLENDER CONFIGURATION PARAMETERS Contd. FEED CAL OPTIONS MECHANICAL OPTIONS FEEDER SETUP