Sterling A0567659 Technical Assistance

Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 783-7835 or call [262] 641-8600, Fax [262] 641-8653

The ACS Customer Service Group will provide your company with genuine OEM quality parts

manufactured to engineering design specifications, which will maximize your equipment’s performance

and efficiency. To assist in expediting your phone or fax order, please have the model and serial

number of your unit when you contact us. A customer replacement parts list is included in this manual

for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing

excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 783-7835 or call [262] 641-8600

Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most

products.

Sales Department

Call [262] 641-8600 Monday–Friday, 8am–5pm CST

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales

Department for the name of the sales representative nearest you.

Contract Department

Call [262] 641-8600 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services: project planning;

system packages including drawings; equipment, labor, and construction materials; and union or non-

union installations.

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