Operating Instructions Gravimetric Batch Blending System

Transcription

Operating Instructions
64.10-0268GB02 12/03
Gravimetric Batch Blending System
Ultrablend 75
with UB Touch
Colortronic GmbH
UB 75
Colortronic GmbH
Otto-Hahn-Straße 10-14
D-61381 Friedrichsdorf
Telephone (0 61 75) 7 92-0
Telefax (0 61 75) 7 92-1 79
Email info@colortronic.de
Http://www.colortronic.com
USA
Colortronic North America Inc.
155 E., 9th Avenue
Runnemede, NJ 08078
Telephone (856) 312-9600
Telefax (856) 312-9696
Email ctusa@colortronic.com
Technical service:
Service department
Telephone: (0 61 75) 7 92-2 22
Telefax: (0 61 75) 7 92-1 19
Email service.d@colortronic.de
Spare parts department
Telephone: (0 61 75) 7 92-3 33
Telefax: (0 61 75) 7 92-1 08
64.10-0268GB02 12/03
Edition: 12/03
Order number: 64.10-0268GB02
Colortronic order confirmation number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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64.10-0268GB02 12/03
UB 75
Colortronic GmbH retains all rights to change the Copying, translation or publication in any form
information in these operating instructions at any except for personal use of purchaser requires
time without notice.
approval from Colortronic GmbH.
We assume no liability for any errors or direct or in- All rights reserved.
direct damage resulting in context with these operating instructions.
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UB 75
Table of contents
1. General Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.
1.2.
1.3.
1.4.
1.5.
Warning Messages and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Explanations and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Legal basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Fields of applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Notes on Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2. For the safety of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3. Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
Switching on the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
The Operation at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Overview: Target -/Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Menu Basic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Dosing Unit Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Process Current Recipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
To Edit Recipes in the Memory of Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.7.1. Load Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.7.2. Clear Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.7.3. Edit Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8. View Event Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.9. Starting Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.10. Switching off the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4. Error and error correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
64.10-0268GB02 12/03
5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Emptying the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Adjusting the Level Probes (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Checking the Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Calibrating and Taring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4
UB 75
6. Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1. General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.2. Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.3. Touch screen operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2. Operation at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3. Setting the Basic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.1. System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4. Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5. Trend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
7. Transport, Assembly and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1. Transport and Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
8. Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1. Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2. Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9. Description of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1. Ultrablend 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2. Method of Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2. Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.1. Switch Cabinet (E-Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3. Refilling System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
10. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
64.10-0268GB02 12/03
11. Service Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
5
UB 75
12. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
o _____________________________________________
o_____________________________________________
o_____________________________________________
o_____________________________________________
o_____________________________________________
64.10-0268GB02 12/03
o_____________________________________________
6
UB 75
1. General Instructions
These operating instructions must be used by every person charged with
work on the unit.
64.10-0268GB02 12/03
»
These instructions are addressed to all users of the device.
General Instructions 1-1
UB 75
1.1. Warning Messages and Symbols
The following warning messages and symbols are used in these operating instructions:
»
L
F
This symbol indicates danger to life! Fatal or serious injury is possible if the
corresponding instructions, regulations or warnings are not observed.
This symbol indicates that serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
This symbol indicates that extensive damage to equipment is possible if the
corresponding instructions, regulations or warnings are not observed.
This symbol indicates information important for becoming familiar with the
equipment, i.e. technical correlations.
$
This symbol indicates that a technical term is explained at this point.
64.10-0268GB02 12/03
&
UB 75
1.2. Explanations and Definitions
In this operating manual, certain terms are used repeatedly for better clarity. Therefore please keep
in mind that these terms stand for the explanations given here.
•
Equipment
“Equipment” can mean an individual unit, a machine or an installation.
•
Operating personnel
The “operating personnel” are persons operating the equipment on their own responsibility or
according to instructions.
•
Operator
The “operator” of the equipment (production
manager, foreman, etc.) is the person responsible for all production sequences. The operator
instructs the operating personnel of what is to be
done.
•
Operating instructions
The “operating instructions” describe the interaction of the equipment, production sequences or methods. The operating instructions must be compiled by the operator of the
equipment.
•
Equipment foreman
When several operating personnel work on
one machine, the “equipment foreman” coordinates the sequences. The equipment foreman
must be appointed by the operator.
•
Trained personnel
“Trained personnel” are persons who, due to
their training, are authorized to carry out the required work.
1.3. Legal basis
See “Manufacturer’s Certificate” resp. “Certificate of Conformity”.
1.4. Fields of applications
The Ultrablend 75 is ideally suited for blending granulates, additives and regrinds.
High dosing accuracy and consistency improves end product quality and saves money by using less
additives and reducing scrap.
The Ultrablend 75 is specially designed for direct mounting on small injection molding machines and
extruders. All products are dosed and weighed one after each other into a weigh hopper supported
by a single load cell. Once all components are weighed, they are passed to the mixing chamber
where they are homogenized before exiting the blender.
64.10-0268GB02 12/03
1.5. Notes on Usage
•
Experienced operators of Ultrablend systems
can begin directly with the chapter on “Continuous Operation” if the unit has been properly installed and the initial start-up has been carried
through.
•
If the unit has not been installed yet, observe
the instructions in the chapter on “Installation
Instructions” and “Transport, Assembly and
Storage” . After the installation, carry through
the initial start-up.
UB 75
2. Safety instructions
»
These safety instructions apply to all persons within the range of action of
the equipment.
Please inform all persons within the range of action of the equipment of the
direct and indirect hazards connected with the equipment.
These operating instructions are to be used by all persons assigned activities connected with the equipment.
Knowledge of the English language is prerequisite.
64.10-0268GB02 12/03
Ensure in each case that the operating personnel are familiar with the operating instructions and the function of the equipment.
Safety instructions 2-1
UB 75
2.1. For your safety
General
Assembly
The operating personnel of this equipment must Compare the connected loads with those of the
mains supply. Danger of injury through electrical
be at least 16 years old.
shock!
Please read these operating instructions carefully
before taking into operation for the first time. Con- When using lifting gear, please observe the pertact us should questions arise. This avoids injury taining regulations. Caution: Danger of accidents!
and damage to equipment!
These operating instructions must be kept available at all times at the place of operation of the
equipment. Improper operation results in danger
of accidents!
Do not modify, add other equipment or change
the design of the equipment without the approval of the manufacturer. Caution: Danger of
accidents!
Please note that, for reasons of clarity, not all con- Attachments not supplied by Colortronic must
ceivable cases regarding operation or mainte- be manufactured in accordance with safety regnance of the equipment can be covered in these ulation EN 294. Danger of accidents!
operating instructions.
When installing the device, keep in mind that it
Please observe all safety instructions and warn- could be top-heavy. Danger of tilting over!
ings on the equipment. This avoids injury and
If PVC hoses are used for conveying, they must
damage to equipment!
be grounded. This avoids injury and damage to
The proper working clothes are to be worn during equipment!
any work on the equipment. This avoids injury!
The local regulations and requirements pertaining
to this equipment must be observed.
Disconnect electrical components from the mains
supply before work is carried out on these components Caution: Danger to life through electrical
shock!
Compile detailed operating instructions based on
these Operating instructions for the sequence of
procedures to be carried out on this equipment.
Improper operation results in danger of accidents!
The safety instructions of the connected machines must be followed.
64.10-0268GB02 12/03
Observe that sound intensity levels over 85 dB(A),
may cause prolonged damage to health. Use suitable earmuffs! This prevents ear damage!
UB 75
Operation
Maintenance
Appoint an equipment foreman to be responsible Before starting maintenance work, appoint a supervisor.
for the equipment.
Ensure that the operating personnel are provided Inform the responsible personnel before maintedetailed instruction in the operation of the equip- nance work on the system is started.
ment. Improper operation results in danger of ac- Caution: Danger of accidents!
cidents!
Disconnect the equipment from mains supply
When the main switch is switched off for reasons before starting maintenance procedures to enpertaining to safety, it must be secured against un- sure that it cannot be switched on unintentionauthorized activation. Caution: Danger of acci- ally. Caution: Danger of accidents!
dents!
Check all lines, hoses and screwed conections
Repair works may only be carried through by qual- regularly for leaks and obvious damage. Repair
damage immediately. Caution: Danger of acciified staff. Danger of accident!
dents!
Never operate the device if it is partially dismantled. Danger: limbs may be caught in machinery! Depressurise all compressed air piping before
starting maintenance work. Danger of acciDanger of electrical shock!
dents!
In the case of malfunctions, switch off the device
immediately. Faults must be eliminated as soon When cleaning the mixing chamber or handling
the mixing arm be careful, the blades of the mixas possible. Danger of accident!
ing arm are sharp. Always wear leather gloves!
The device is intended exclusively for processing Danger of injury exists!
plastic granules and additives. Different or addiWait at least one minute before starting to work
tional usage is not permitted.
at the switching cabinet. Danger to life! DisThis device is not suitable for the processing of charge of high-voltage possible!
foods.
Conveying units must be removed before startThe equipment may only be operated when all the ing maintenance. This avoids injury and damassociated components are properly connected age to equipment!
up and in accordance with the relevant regulations. This avoids injury and damage to equip- Never open the lids of the dosing hoppers when
a conveying unit is mounted. Danger of tilting
ment!
over!
Operate the device only if all its components are
grounded. Danger: accident through electrical
shock!
64.10-0268GB02 12/03
Never put your hand into the shutter of the refilling
system. Danger: limbs may be caught in machinery!
Never reach into the weighing container during
operation or without switching off the main switch.
Danger: limbs may be caught in machinery!
UB 75
2.2. For the safety of the devices
Never change settings without carefully assess- A compressed air supply is necessary for operating the device.
ing the consequences.
Use only original Colortronic spare parts.
Observe the maintenance instructions.
Never set the operating pressure at more than
6 bar (system overpressure).
Note down all setting data.
Keep a record of all maintenance works and reNote that, if the batch weight put into the device
pairs.
is too great, the weighing container may spill
Please note that electronic components may be over.
damaged by static discharge.
Please ensure that all plugs are correctly
Before initial operation and in regular intervals, plugged in.
make sure that no electrical connections are
The operating instructions of the connected maloose.
chines must be followed.
Never readjust sensors without exactly knowing
All components must be sufficiently grounded.
their functions.
Use only original Colortronic cables during instal- Tell the password only to authorised persons.
lation and repair works, since those are precisely
Never open the lids of the dosing hoppers when
adapted to the system.
a conveying unit is mounted.
During installation, respect the load-bearing caThis device is not suitable for the processing of
pacity of the installation site.
powder.
Operate the control system only with temperatures between -10 and +50°C (14 to +122 °F).
64.10-0268GB02 12/03
Store the control system only with temperatures
between -25 and +70°C (-13 to +158 °F).
UB Touch
3. Continuous Operation
Version: 64.10-0266GB02 12/03
»
This chapter is intended for experienced users who are familiar with Ultrablend systems.
Prerequisite for this chapter is general knowledge of the use of dosing and
blending units.
Prerequisite for this chapter is that the initial start-up has been carried
through.
Prerequisite for this chapter is that the installation has been carried
through.
Also prerequisite for this chapter is that the description of functions has
been read and understood.
Ensure in each case that the operating personnel are sufficiently informed.
F
$
If you use Ultrablend blending system for the first time:
Follow step by step the points as specified in the chapter “Initial Operation”.
The graphical display of the unit depends on the number of dosing units!
64.10-0266GB02 12/03
Make sure that with your control the display of the dosing units is in continuous analogy with the number of dosing units.
Continuous Operation 3-1
UB Touch
3.1. Switching on the Unit
Switch on the unit at the main switch.
&
The control system carries through a self-test. This may take a few seconds.
64.10-0266GB02 12/03
The info menu is shown for a short period of time and subsequently the
“overview” menu.
UB Touch
64.10-0266GB02 12/03
3.2. The Operation at a Glance
for info menu s. chapter 6
for selection menu s. page 9
for alarm/event menu s. page 15 & ch. 4
for current recipe menu s. page 7
for basic module menu s. page 5
for dosing unit module s. page 6
Overview: Target -/Actual Values
3.3. Overview: Target -/Actual Values
E
D
C
B
A
R
F
G
H
I
J
K
L
A
Alarm/event protocol
B
Active faults
N
O
P
Q
I
Consumption in kg per dosing unit since last “zeroizing consumption”.
J
C
Menu “current recipe”.
D
Name of recipe
E
Lock open, green: Password-protected entries can be made;
Click to “logout”: Lock closed, red: Password-protected entries
cannot be made.
System menu
Info menu
Status display
Booting up / initialising
Turned off
Automatic operation
64.10-0266GB02 12/03
M
K
L
M
Consumption in kg of all dosing units since last “zeroizing consumption”.”
N
LED red: Fill level in machine hopper reached
O
Stop cycle is terminated
Present capacity in kg/h
Alarm
LED red: Max. fill level in machine hopper not reached; another emptying of the scale is possible;
LED green: Max. fill level in machine hopper reached
P
Alarm stop: With lack of material
an alarm is triggered and the unit is stopped: Q
Weight in g presently inside the weighing container (incl.tare)
Press START key
F
Portions of target values / percentages per dosing unit
G
R
LED green: Fill level in dosing hopper reached
LED red: Fill level in dosing hopper not reached.
Calculated target value in g per dosing unit
H
Actual value in g per dosing unit
UB Touch
3.4. Menu Basic Module
&
This function is password-protected.
Batch weight (Password level 3)
Enter the batch weight to be metered per cycle in g.
If you enter a batch weight which is too high, the
weighing container can overflow.
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Mixer Mode (Password level 4)
Enter the operating mode of the blending unit:
Off = blending unit off
Continuous operation = continuous operation
Pulse pause operation= pulse pause operation (the blending unit operates in intervals, ratio 1:1)
Maintained running time = maintained running time of
blending unit (the blending unit operates only if the weighing container has been emptied).
Time
Enter the blending unit time in seconds
(see maintained running time of blending unit or pulse
pause operation, respectively).
Quantity (Password level 4)
Display of total quantity of material for quantity operation
(for activation of quantity operation s. chapter 6).
If the quantity operation is activated a fault is reported
when the set amount of material has been reached, or
the fault is reported and the unit is stopped (see configuration quantity operation).
Consumption = 000
Consumption zeroizing: the total consumption of all dosing units and the consumption per dosing unit are zeroized. Additionally, trend data and capacity are cleared.
UB Touch
3.5. Dosing Unit Menu
&
This function is password-protected (Password level 3).
Parts
64.10-0266GB02 12/03
Enter the portions/percentage values of the respective
dosing unit.
UB Touch
3.6. Process Current Recipe
&
Parts (Password level 5)
dosing unit.
Material (Password level 4)
Enter the type of material to be processed by the respective dosing unit:
regrind
raw material
additive
MG (Probe) = regrind, sensor controlled
The type of material and the order are important for
the corrective calculation by the control system;
the best order is: regrind, raw material, additive.
Alarm hand. (Password level 4)
Enter the type of alarm of the respective dosing unit:
No alarm: No alarm message with a lack of material and
no stopping of the unit.
Warning: With a lack of material, an alarm message is given, but the unit is not stopped.
Alarm stop: With a lack of material, an alarm message is
given and the unit stops.
Next
To next side of menu.
Close
64.10-0266GB02 12/03
To “overview” menu.
UB Touch
Name (Password level 4)
Enter name of material.
Dos. Speed (Password level 4)
Enter the dosing speed for each dosing unit (1-6).
The dosing speed indicates how much material is
dosed per second. Normally, the dosing speed is
re-determined for each dosing process.
Change the value of the dosing speed only if you
have changed the feed station.
During the first 5 cycles, Ultrablend is calibrating;
therefore, greater deviations might occur.
Back
leads to previous side of menu.
Next
leads to next side of menu.
Close
leads to menu “overview” without taking over the values.
Name (Password level 4)
Enter name of recipe.
Batch weight (Password level 4)
Mixer Mode (Password level 4)
Pulse pause operation = pulse pause operation (the blending unit operates in intervals, ratio 1:1)
Time
Back
Close
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Save (Password level 3)
Click “save” to save current recipe.
UB Touch
3.7. To Edit Recipes in the Memory of Recipes
&
The memory of recipes has a maximum of 50 different slots for recipes.
Recipe
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Display of the selected recipe.
UB Touch
3.7.1. Load Recipe
&
Select desired recipe in memory of recipes (01-50).
Load (Password level 4)
load recipe.
The selected recipe is loaded from the
memory of recipes and then is the presently used recipe. Subsequently the
menu “overview” is displayed.
64.10-0266GB02 12/03
&
UB Touch
3.7.2. Clear Recipe
&
Clearing (Password level 3)
clear recipe.
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&
The selected recipe is cleared. Subsequently the menu “overview” is displayed.
UB Touch
3.7.3. Edit Recipe
&
This function is password-protected (password level 3).
Input
load recipe.
The selected recipe is loaded.
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&
UB Touch
Parts
dosing unit.
Material
Enter the type of material to be processed by the respective dosing unit:
regrind
raw material
additive
MG (Sonde) = regrind, sensor controlled
The type of material and the order are important for
the corrective calculation by the control system;
the best order is: regrind, raw material, additive.
Alarm hand.
Enter the type of alarm of the respective dosing unit:
No alarm: No alarm message with a lack of material and
no stopping of the unit.
Warning: With a lack of material, an alarm message is given, but the unit is not stopped.
Alarm stop: With a lack of material, an alarm message is
given and the unit stops.
Back
Next
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Close
UB Touch
Name
Enter name of material.
Dos. Speed
Back
Next
Close
Name
Enter name of recipe.
Batch weight
Mixer Mode
Pulse pause operation= pulse pause operation (the blending unit operates in intervals, ratio 1:1)
Time
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Back
Close
Save
Click “save” to save current recipe.
UB Touch
3.8. View Event Protocol
&
This function is not password-protected.
Events (faults/alarms or production reports, 01-50) are
displayed with
- Date (DD.MM),
- Time (hh:mm:ss),
- Text information with number of dosing unit,
- Code “C”, “G” or “A”.
&
“C” = comes (= an event
has happened, red))
“G” = goes (=the cause of the event
has been eliminated, green)
“A” = acknowledged (the display
of the event report was
acknowledged, blue)
The most current event is placed at the top.
Acknowledge
Acknowledge selected event.
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&
The following events can be displayed:
- Parameters changed
- Recipe changed
- Recipe cleared
- Recipe incomplete
- Memory of recipes full/empty
- Recipe activated
- Recipe saved
- Name of recipe double
- Unit started / stopped
- Consumption cleared
- Initialised
For alarm protocol s. chapter 4
UB Touch
3.9. Starting Continuous Operation
Switch on the compressed air supply.
Start the refilling system, if available (conveying system).
F
Check whether the material hoppers are sufficiently filled with material.
Check whether the basic parameters of the control system have been set.
Check whether the correct operating mode is set.
Check whether the correct recipe is active.
press.
3.10. Switching off the Unit
Wait until the current dosing process is finished.
press.
&
Symbol flashes and goes out.
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Switch off the unit at the main switch.
Switch off the compressed air supply.
If available, stop the refilling system (conveying system).
UB Touch
4. Error and error correction
Version: 64.10-0266GB02 12/03
»
This chapter is intended for the operating personnel of the equipment.
blending units..
The “Start-up” description must have been read and understood.
64.10-0266GB02 12/03
F
Any faults must be eliminated immediately.
Error and error correction 4-1
UB Touch
&
This function is not password-protected.
Faults/alarms (01-50) are displayed with
- Date (DD.MM),
- Time (hh:mm:ss),
- Text information with number of dosing unit,
- Code “C”, “G” or “A”.
&
“C” = comes (= a fault has happened, red)
“G” = goes (=the cause of the fault
has been eliminated, green)
“A” = acknowledged (the display
of the fault report was
acknowledged, blue)
The most current fault is placed at the top.
Acknowledge
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Acknowledge selected faults reports.
UB Touch
The following faults can be displayed:
- Battery empty
Remedy
- Safety chain ?
The spurwheel cover of the dosing motor or the
front door are open.
Replace/renew battery.
- Int. Comm ?
Remedy
Remedy
Install the spurwheel cover of the screw feeder
or close the front door, respectively; if necessary, check contact.
Make sure that the motor of the screw feeder is
connected.
Error in component/address allocation, Colortronic service.
Check the communication cable (wrong position,
- Data initialised
possibly a wrong cable).
Wrong software version, Colortronic service.
Remedy
- Hopper # empty
Remedy
When the unit is switched on, this message must
be displayed.
During operation: unit reset
(e.g. EMC problems), Colortronic service.
Check the electrical connection.
Refill material.
Check whether the material flows evenly (e.g. vacuum during conveying, line blocked).
The amount is too small and cannot be metered - Internal Error
with this station; if necessary, prolong the responRemedy
se time.
Colortronic Service
- Mat. # refill
The probe (optional) of the hopper has respon- - Scale oscillates
ded.
Remedy
Refill material.
Check the probe setting; re-adjust, if necessary.
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- Mat. # overdosing
Remedy
Depending on the type of alarm, the unit either
stops and the error must be acknowledged with
the ENTER key (the cycle is continued) or an
alarm message is given or no alarm is given.
Remedy
Increase the measuring interval value. Increase
the value for the scale tolerance range.
During blending, material comes in contact with
the weighing container.
Dampen the Ultrablend. Improve the setup.
New calibration.
The augmentation is too small; the measuring
points are too close together (e.g. min. value
and max. value are equal).
UB Touch
- Scale not calibrated
Remedy
New calibration and taring.
- Scale overloaded
Remedy
Select a smaller value for the batch weight.
The dosing speed oscillates. Check the value for
the dosing speed; increase, if necessary.
If the container is not overcharged, check the
measuring range of the scale.
During calibration, enter wrong weight.
New calibration.
- Emergency Stop! Cycle ?
Emergency stop! The cycle has not been finished.
- Taring ?
Remedy
New calibration and taring.
- Prod. Weight reached
Remedy
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“Zeroizing consumption” or
change the configuration to continuous operation.
UB 75
5. Maintenance
»
This chapter is intended for persons with skills in electrical and mechanical
engineering due to their training, experience and received instructions.
Personnel using this chapter must be instructed in the regulations for the
prevention of accidents, the operating conditions and safety regulations
and their implementation.
Ensure in each case that the personnel are informed.
For maintenance work taking place at heights of over approx. 6 feet, use
only ladders or similar equipment and working platforms intended for this
purpose. At greater heights, the proper equipment for protection against
falling must be worn.
Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capacity. Do not stand or work under suspended loads!
Protect electric motors and switch cabinets sufficiently from humidity.
Use suitable workshop equipment.
Before beginning maintenance work, designate a supervisor.
Before beginning maintenance work, inform the responsible service personnel.
Never operate the equipment when it is partially dismantled.
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All maintenance and repair work not described here may be carried out
only by Colortronic service technicians or trained personnel authorised by
Colortronic.
Maintenance 5-1
UB 75
L
Disconnect the equipment from mains supply before starting maintenance
procedures to ensure that it cannot be switched on unintentionally.
Depressurise all compressed-air lines before starting work on the equipment.
F
Please observe the maintenance schedule.
Before starting maintenance work or repair, clean the equipment of oil, fuel
or lubricants.
Ensure that material and incidentals required for operation as well as replacement parts are disposed of properly and in an environmentally sound
manner.
Use only original Colortronic replacement parts.
64.10-0268GB02 12/03
Keep record of all maintenance and repair procedures.
Maintenance 5-2
UB 75
5.1. Maintenance Intervals
With each
change of material:
clean the weighing container
clean the mixing chamber
check the level probes (optional) for proper adjustment
Daily:
check the device’s danger signs for legibility and completeness
check the compressed-air supply (5-6 bar system overpressure max.)
empty the water separator (optional)
check the oiler (optional)
Every three months:
check the load cells (calibrating/taring)
check the programming
Every six months:
&
The maintenance intervals refer to 3-shift operation.
The given maintenance intervals are average values.
Watch to see whether the maintenance intervals must be shortened in your
specific case of application.
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F
make sure that no electrical or mechanical connections are loose.
Maintenance 5-3
UB 75
5.2. Emptying the Unit
&
Mount the emptying chute (optional) for the emptying process.
# 1-6 / open
Click dosing station you want to empty. Slide valve is
64.10-0268GB02 12/03
opened, LED is green.
Click “open” to close slide valve, LED is red.
Scale /close
Click “scale” to close the weighing container, LED is
green
Click “close” to open the slide valve, LED is red.
M.Mot (= mixer motor) / on
Click “M.Mot” to start the mixer, LED is green.
Click “on” to stop the mixer, LED is red.
M.H (= mixing hopper) / open
Click “M.H” to open the mixing chamber, LED is green.
Click “open” to close the mixing chamber, LED is red.
Maintenance 5-4
UB 75
5.3. Cleaning the Unit
»
Stop continuous operation.
Wait until all dosing units have come to a standstill.
“Empty” the unit (see chapter ”Emptying the Unit”).
Switch off the unit at the main switch.
Interrupt the power supply.
Depressurise all compressed air piping of the unit.
Conveying units must be removed before starting maintenance.
F
Always wear leather gloves when cleaning the mixing chamber or disassembling the mixer arm. The blades of the mixer arm can be very sharp.
This will prevent bodily injury and material damage!
Open the front door.
Open the snap buckle of the compressed air at the
weighing bin.
Be careful when withdrawing the weighing container (A) out of the bracket.
Remove the mixing chamber (B); necessary only
with rough impurities: Lift locking button (C) and
remove mixing chamber with mixer arm.
Clean the dosing hoppers, the weighing container
and the mixing chamber. Use non-fibrous cleaning cloths and/or a brush.
A
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B
C
Maintenance 5-5
UB 75
Assembly
Assemble the mixing chamber (if disassembled): Push the mixing chamber in the housing, lock the
mixing arm in the driving gear, lock the locking button.
Assemble the weighing container, check for proper fit.
Assemble the air hose. Chec k for proper fit: the air hose may not touch or push against other objects.
Close the front door.
5.4. Adjusting the Level Probes (Optional)
F
Observe the operating instructions for the level probe.
5.5. Checking the Programming
Compare all entered values of the control system with your notes.
5.6. Calibrating and Taring
F
64.10-0268GB02 12/03
&
This activity cannot be carried out during continuous operation.
Completely empty the weighing container.
You need a testing weight of 1000 g (UB 75).
If you have no calibrated testing weight, weigh the testing weight with a calibrated scale.
Note down the value.
Maintenance 5-6
UB 75
Taring
&
Actual weight
Display of the weight currently inside the weighing container in g (incl. tare).
The value underneath indicates the tare value.
Max. Diff. Tara
Enter the maximum deviation of the tare value from the
determined value with an empty weighing container.
If the maximum deviation is exceeded, an error
message is given after the flap has been opened 4 times.
Before each weighing procedure, automatic taring
takes place.
Taring
Click “taring” if you want to tare.
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When you tare a new tare value is calculated and
displayed, the “current weight” is zeroized.
Maintenance 5-7
UB 75
Calibrating
&
Zero Point
Measuring point without weight, i.e. only the weighing
container.
Make sure that the weighing container is clean.
Click “Zero Point” to determine the measuring point.
Display current weight : “0.0”
Calibration weight
The weight for determining the value with the high load
factor of the load cell.
Enter the value of the testing weight.
Max.Point
Measuring point with maximum load factor of the load
cell, i.e. with calibration weight & weighing container.
Place the testing weight into the weighing container
(observe max. load UB 75: 1 kg).
Wait until the display has stabilised.
Click “Max. Point” to determine the max. point.
The current weight of the testing weight is displayed.
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After the testing weight has been removed, the current weight must again be “0"; otherwise you must
tare.
DMS /
internal service value, the value must rise as soon as the
scale is loaded.
Faktor / Offset
internal service values
Maintenance 5-8
UB Touch
6. Initial Start-Up
Version: 64.10-0266GB02 12/03
»
This chapter is intended for operating personnel.
blending units.
Prerequisite for this chapter is that the installation has been carried
through.
Also prerequisite for this chapter is that the description of functions has
been read and understood.
64.10-0266GB02 11/03
Initial Start-Up 6-1
UB Touch
6.1. Control
The control of the unit is programmed in the factory. Nevertheless, you need to set some specific parameters (basic setting) which, among other things, depend on the processed material.
Central control is possible for as many as 6 dosing units.
The set parameters are saved and remain preserved also when the unit is turned off or in the case of
power failure.
6.1.1. General Operation
Touch screen
B
Number pad for entry
C
Start key
Starts the line
D
Enter key
Acknowledges entries
E
Stop key
Stops the line
F
Escape key
Interrupts entries
G
I
A
B C D E FG H
Alarm acknowledgement
H
Back space key
Clears last entry in entry window
I
Info menu, short information on basic meaning of keys
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6.1.2. Entries
Entries only are taken over after having been acknowledged with the enter key.
UB Touch
6.1.3. Touch screen operation
The operation menu is selected on the monitor by touching the symbols with the tips of the fingers.
Entries are made on the number pad.
As soon as a symbol is touched the corresponding menu appears.
As soon as an entry window is touched it is activated and entries can be made.
open menu
browse
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close menu
UB Touch
64.10-0266GB02 11/03
6.2. Operation at a Glance
for info menu, s. page 2
for selection menü, s. page 6
for alarm/event menu, s. chap. 3 & 4
for menu current recipe, s. chapter 3
for menu basic module, s. chapter 3
for menu dosing unit, s. chapter 3
UB Touch
6.3. Setting the Basic Parameters
Before putting the control into operation for the first time, you must carry through a basic setting. This
basic setting is registered by the control system and remains valid even after a power fail.
F
If problems should occur during subsequent use, you can change the factory setting of the data which cannot be modified here, namely in the chapter
”Service Settings”.
&
In the description of the basic settings entry, it is presumed that you enter all
values.
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This function is available only from password level 3 upwards.
UB Touch
6.3.1. System
Main
Language
Select the desired language.
Date / Time
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Enter date / time of day.
System
Enter name of unit.
Version
Display of version of software.
UB Touch
Regrind
Regrind Mode
Select mode priority switching of material to be ground
not active
not active
from granulator
In the dosing station a probe must be present.
If the probe is covered, the portion of regrind increases
after the adjustable delay per dosing cycle. The maximum value is determined by the addition of the tolerance
[%] and the regrind desired value [%].
If the probe becomes again free, the portion of regrind degrades itself after the adjustable delay per dosing cycle.
The minimum value is determined by the subtraction of
the tolerance [%] by the regrind desired value [%].
If no probe change should take place after an adjustable
number of dosing cycles, an error message is displayed.
&
The regrind varies around the desired
value in the adjustable tolerance.
The granulator may not be overfilled.
from silo
&
The function is not active at present.
Component
64.10-0266GB02 11/03
Dosing station with material to be ground which is to be
controlled in the mode “priority for material to be ground”.
Tolerance
Aadmissible tolerance (+/-) for the control of material to
be ground.
Steps Number
Nnumber of steps to reach the max. tolerance.
Delay
Number of delay steps (dosing cycles) subsequently to
the exchange of a probe until an adjustment is made.
Delay Alarm
Number of cycles subsequently to exchange of probe until a fault is reported. Alarmmeldung erfolgt.
UB Touch
Level
Waiting Time
Enter the minimum time which should pass, after the mixing chamber has been complete filled (the level probe is
covered), until the slide valve under the mixing chamber
opens in case of a message of the discharge level probe.
The time is needed for mixing the material before it is
made available to the processing machine.
For an activated blending unit, always select a waiting time which is longer than the blending time.
Empty Out Time
Enter for how long the slide valve for emptying the mixing
chamber should stay open. The slide valve opens only if
the probe (optional) in the collecting/machine hopper is
not covered. As soon as this probe is covered, the slide
valve closes.
64.10-0266GB02 11/03
The next cycle begins as soon as the mixer level
probe is not covered by material.
Emptying out is done when the level probe is not
covered.
For a container underneath the Ultrablend the
empty out time = the time needed to refill the container.
UB Touch
Config
Quantity Mode
Enter the operating mode during quantity operation:
Continuous operation = no quantity operation
Alarm àquantity = When the entered quantity is reached,
an alarm message is given, but the device keeps on dosing.
Stop àquantity = When the entered quantity is reached,
the device stops operating and an alarm message is
given.
Dosier.
Enter the desired type of dosing for the device:
Gravimetr. = gravimetric dosing
Volumetr. = volumetric dosing
Gravi-/Volumetr. = ”combined gravimetric and volumetric
dosing (mix)
No cycles in volum.
Enter how many volumetric dosing cycles should take
place in the ”mix” mode between 2 gravimetric dosing cycles (only for dosing type “mix”).
Volumetric and mix dosing are normally employed if
materials have to be dosed quickly but the mixing
ratio does not have to be very exact.
As long as the mixing chamber is filled, dosing automatically takes place in the gravimetric mode.
64.10-0266GB02 11/03
Mixer Frequency (UB 75)
Enter cycle time of mixer in seconds (only for pneumatic
mixers, e.g. UB 75).
Setting the Basic Parameters
Dos. Speed
Tolerance [%]
Range of tolerance (dosing speed)
Enter the maximum permitted deviation of the current
dosing speed from the last one measured.
The new dosing speed is only accepted if the new
calculated value after dosing is within the range of
tolerance.
Speed [g/s]
Dosing speed
Set Default
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Click “set default” to save the entered values for dosing
speed as standard values.
UB Touch
Display
Actual values in
Select whether values are to be displayed in “g” or in “%”.
Display: gram
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Display: % / portions
UB Touch
6.4. Printer
&
Standard setting of the printer interface: 9600 Baud, no parity, 8 bit, 1
stopbit).
Check if a printer (optionally) is connected.
This function is available from password level 4 on.
Printing
Select operation mode of printer (optionally)
-Off
- Current recipe
- Recipe (Select name of recipe)
- All recipes (Only the names of all recipes in the list
of recipes are printed)
- Consumption
- New page (= form feed)
- System / service
Click “print” to start the print-out.
Protocol
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Select which information you want to be printed out in
the case of each event:
- Off
- Consumption
- Dosing
- File CSV (print in file)
UB Touch
6.5. Trend
&
Trend helps you with statistic analyses and with statements on the dosed
quantity in g in each dosing unit.
A maximum of 50 dosing cycles can be recorded.
Enter min.-/max. values.
New
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Click “new” to activate demonstration.
UB 75
7. Transport, Assembly and Storage
»
This chapter is intended for all operating personnel of the equipment.
Personnel using these instructions must be instructed in the regulations
for the prevention of accidents, the operating conditions and safety regulations and their implementation.
Please inform all persons within the range of action of the equipment of the
direct and indirect hazards connected with the equipment.
64.10-0268GB02 12/03
Please observe all safety regulations for the operation of lifting equipment.
Transport, Assembly and Storage 7-1
UB 75
7.1. Transport and Packing
»
Please ensure adequate carrying capacity of the lifting equipment.
The unit is delivered as a complete system on a pallet. Only the weighing container must still be assembled after installation.
If a refilling system is part of the delivery (optional), it must be assembled as well.
The equipment pass a rigorous operating test in the factory and are packed carefully to avoid transport damage.
Please check packing on delivery for transport damage.
The inlet and discharge flanges are sealed with plugs, so that no dirt can enter during transport.
Plugs must be removed before assembly.
Packing materials should be disposed of according to environmental laws or reused.
Only use for transport of the equipment a suitable lifting device (e. g. a fork lift truck or a workshop
crane).
For transport of control cabinets fasten the transport cables to the eyelets of the control cabinets
64.10-0268GB02 12/03
Transport must be shock-proofed and free from vibrations.
UB 75
7.2. Assembly
»
Please ensure adequate carrying capacity of the lifting equipment.
Check the carrying capacity of the point of installation, particularly if installed on a platform.
The place selected for installation should be as free of vibrations as possible.
The main switch must be freely accessible.
Ground the equipment against electrostatic charging.
When installing the unit, keep in mind that it may not touch or push against other objects so that no results are falsified during subsequent use. This holds good especially for the installation of a refilling
system.
F
After the installation, assemble the weighing container.
The device is delivered as a complete unit system. Due to the measuring principle (direct measurement), the unit can be assembled by means of a standard flange (150 mm x 150 mm) or a customised
flange directly on the feed opening of the extruder. For injection moulding operation, the unit should
be installed next to the processing machine. In case of assembly directly on the feed opening of the
injection moulding machine please contact Colortronic service. Installation on a scaffold above the
extruder / the injection moulding machine is possible.
F
The base plate must have a thickness of at least 15 mm.
Observe the load bearing capacity of the installation site.
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The hoppers are mounted on the joining pipe of the unit.
&
Additional extension modules can be mounted with snap buckles.
UB 75
The control unit is located in a switch cabinet attached to the unit housing. The operation panel
can be used as desk panel or in combination with a mounting plate (optional) be hung up.
Install the control unit well visible and easily accessible. Select the site of installation in such a way
that the Ultrablend can be seen from the control unit and any errors can be eliminated more easily.
The switch cabinet / the control unit may not be subjected to vibrations, humidity or heat.
7.3. Storage
The control system may only be stored at temperatures from -25 to +70 °C (-13 to +158 °F).
64.10-0268GB02 12/03
Between delivery and machine commissioning the equipment should be stored in a dry, dust-free
and vibration-free room.
UB 75
8. Installation Instructions
»
These installation instructions are intended for persons with skills in electrical and mechanical engineering due to their training, experience and received instructions.
Personnel using these installation instructions must be instructed in the
regulations for the prevention of accidents, the operating conditions and
safety regulations and their implementation.
Ensure in each case that the personnel are informed.
The installation instructions provided in the corresponding operating instructions apply for all connected equipment.
Observe the safety regulations pertaining to the use of lifting gear.
The equipment must be disconnected from electrical power and compressed air supply before any work is carried out on the equipment.
L
For installation work taking place at heights of over approx. 6 feet, use only
ladders or similar equipment and working platforms intended for this purpose. At greater heights, the proper equipment for protection against falling
must be worn.
Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capacity. Do not stand or work under suspended loads!
64.10-0268GB02 12/03
Use suitable workshop equipment.
F
Install the device in such a way that all parts are readily accessible in order to
facilitate maintenance and repair work as much as possible.
Installation Instructions 8-1
UB 75
8.1. Electrical Connection
»
The regulations of the local Electricity Board must be observed.
Before connection to the electricity supply, it should be ensured that the
supply voltage and the power frequency are in accordance with the data
on the name plate of the machine.
The electrical connection may only be carried out by Colortronic service
staff or trained personnel authorised by Colortronic.
It is not permitted for other persons to undertake the electrical connection.
The main switch must be freely accessible.
Ground the equipment against electrostatic charging.
F
Regularly check all electrical and screw connections for proper fit.
Standard voltage: 115 / 230 VAC, 50 / 60 Hz
special voltages on request
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Install all cables of the unit in such a way that no disturbances can be caused by other electrical systems.
UB 75
8.2. Compressed Air Supply
A compressed air supply is needed to operate the proportioning slide valves.
Check whether the compressed air piping has been installed and connected properly.
Check whether fittings, length and quality of the hose assemblies are in accordance with the requirements.
The operating pressure is 5-6 bar (system overpressure).
Check the compressed air in the factory ductwork system.
Set the air pressure at 5-6 bar (system overpressure).
Attach the compressed air main to the unit.
Depressurise the compressed air piping of the unit for all types of work.
F
The compressed air has to be dewatered and dustfree.
The compressed air can be oiled.
Set the system at a maximum of 6 bar (system overpressure).
64.10-0268GB02 12/03
L
UB 75
9. Description of Functions
»
This description of functions is addressed to the users of the device.
This description of functions requires general knowledge of how to handle
extruders/injection moulding machines.
64.10-0268GB02 12/03
Make sure in each case that the users have the necessary skills.
Description of Functions 9-1
UB 75
9.1. Ultrablend 75
Colortronic’s gravimetric batch blender Ultrablend 75 is ideally suited for blending granulates, additives and regrinds with direct mounting on small injection molding machines, blow molding machines
and extruders.
The Ultrablend 75 is well suited to low rate extrusion applications that do not use powders or require
loss-in-weight blending technology. The blender can be mounted directly on the feed throat or on a
starve feeder.
9.1.1. Structure
The Ultrablend can be equipped with up to 4 dosing units. As an option, it is possible to equip the individual storage receptacles of the dosing units with filling level probes.
The weighing container rests on one load cell.
A horizontal blending unit is installed underneath the weighing container.
There is a filling level probe in the mixing chamber. The weighing container can be emptied only if
this filling level probe is not covered.
64.10-0268GB02 12/03
There is an option of installing a pneumatic slide valve for evacuation of the mixing chamber underneath the unit. This slide valve can be controlled by means of another filling level probe.
UB 75
9.1.2. Method of Functioning
Colortronic’s gravimetric batch blender Ultrablend 75 improves process quality and saves money
through the application of high dosing accuracy and mixing. All products are dosed and weighed one
after each other into a weigh bin supported by a single load cell. Once all components are weighed,
they are passed to the mixing chamber where they are homogenized before exiting the blender.
The Process Begins:
The process begins with the dosing hoppers filled
with material and the weigh bin and mixer empty.
Dosing hopper
Slide valve
Load cell
Weigh bin
Dump valve
Level sensor
Mixer
B
A
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Dosing of Components:
Component A is dosed into the weigh hopper first
via a slide valve. The amount of material dosed is
controlled by the recipe and batch weight. Once
the correct amount of Component A is dosed, then
Component B is dosed in the weigh bin on top of
Component A. This process continues until all
components, up to four, are dosed.
UB 75
Mixing Begins:
Once all the components are dosed into the weigh
bin properly, the dump valve opens and discharges the weigh bin contents into the mix hopper. The mixer combines the individual components into one homogenous mix.
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Dosing and Mixing:
The dosing cycle begins again while the mixing
continues until the high level point in the mix hopper is reached. At this point the process stops.
The process will restart when the processing machinery below takes material from the mix hopper
and the material level drops below the low level.
UB 75
9.2. Control System
The control system is a controller for the central operation of maximally 6 dosing units.
9.2.1. Switch Cabinet (E-Box)
The switch cabinet is attached to the housing of the Ultrablend. It contains the control units and optional control extensions.
9.3. Refilling System (Optional)
A refilling system makes it possible to fully automate the filling of the material hoppers. The material
is automatically refilled in combination with a conveyor unit.
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As conveyor units, Colortronic single conveyor units as well as Colortronic multiple conveyor units
can be used. By means of a universal flange, an existing conveying system can be assembled as
well.
UB 75
10. Technical Data
Ultrablend 75
Basic Version
•
•
•
•
•
•
•
•
•
Up to four dosing components
Weigh hopper volume: 1 Liter
Mixer volume: 3 Liters
Dosing hopper volume: 6 Liters
Maximum throughput (with 2 components): 75 kg/hr
Operating voltage: 115 / 230 VAC, 50/60Hz
Air pressure: 6 bar
Weight (with 4 components): 35 kg
Noise level max. 70 dB (A)
Controller
•
•
•
Menu driven operator interface
•
Display of individual component or total blend
throughput
•
•
Historical event log with time stamp
Historical recording of the last 50 weighing cycles
Ability to input production run weight and stop
blender when production run is complete
Printer interface
Optional Features
Manual or pneumatic slide gate under blender
Level sensor control of slide gate below the blender
Hopper extension modules
Conveying systems
Level sensors in dosing hoppers
Machine adapters
Special voltages
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•
•
•
•
•
•
•
Technical Data 10-1
UB 75
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Dimensions
All dimensions are in mm. Subject to alteration.
Technical Data 10-2
UB 75
UB Touch
Basic Version
Optional Features
•
•
•
•
Lit diagramable Touch screen display
•
•
•
•
Adjustable mixing interval control
•
Permissible storage temperature:
-25 to +70°C / -13 to +158 °F
•
Dry contact alarm output in central control system
•
RS 232/V24 for printer connection
Data buffer in case of power failure
Real-time clock
Interfaces:
Mod bus (central control system)
Profibus DP
Webable
A maximum of 6 dosing stations can be conFunctions
trolled
Type of protection: IP 54
Permissible operating temperature:
-10 to +50°C / 14 to +122 °F
•
•
•
•
•
•
•
•
Menu-driven operation
Multi level password protection
Recipe memory for a maximum of 50 recipes
Event journal
Alarm journal
Display of single material consumption
Display of total material consumption
Desired / actual value display
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145 mm
230 mm
All dimensions are in mm. Subject to alteration.
Technical Data 10-3
UB Touch
11. Service Settings
Version: 64.10-0266GB02 12/03
F
All service settings have already been carried through ex works and normally do not have to be changed.
Service settings may only be modified if the factory settings are too general
for special requirements.
Service settings may only be altered on consultation with the Colortronic
service since these settings are of decisive importance for the operational
safety of the device.
Precise knowledge of the control, the dosing process, the mechanics of the
device and of processing machines are required for entering service settings.
Ensure in each case that the staff are informed.
Service settings cannot be changed during automatic operation.
64.10-0266GB02 12/03
&
Service Settings 11-1
UB Touch
Dosier.
&
Repeatitions
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Enter how often a dosing process should be repeated if
the dosed amount lies beneath the range of tolerance. If
the set amount is not yet reached after the last repetition,
an alarm message is given (if activated).
Tolerance [%]
Range of tolerance (dosing)
Enter the maximum permitted deviation from the desired
dosing value. If the measured value is outside the range
of tolerance, the dosing process is repeated. No new dosing speed is calculated if the weighing result is not inside the range of tolerance. An error message is given depending on the alarm setting for the component.
UB Touch
Scale
&
Max. Weight
Enter max. weight in scale.
MeasureTime Min
Minimum measuring interval for the scale
Enter the length of time the material is to be weighed after
dosing.
If during the measuring interval all consecutive values
measured by the weighing cell (sampling rate approximately 0.1s) are within the tolerance limits, the measuring process is completed.
Measure Time Max
Maximum measuring interval for the scale
Enter the length of time the material is to be weighed after
dosing.
If during the measuring interval all consecutive values
measured by the weighing cell (sampling rate approximately 0.1s) are within the tolerance band, the measuring
process is completed.
Tolerance band
Range of tolerance (scale)
Enter the maximum permitted deviations of the individual
measured values of a weighing process.
Only load cell measuring points within this range of tolerance are taken into account when the weight is determined.
Empty Out Time
Enter for how long the weighing container should stay
open during discharge.
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After this time has passed, the weighing container must
be completely empty (see also Tolerance Range Tare).
UB Touch
Config 1
&
Start Mix. Sensor uncov.
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Select “yes” if cycle is to be started as soon as mixer level
is uncovered.
Select “no” if cycle is to be started as soon as weighing
container is emptied (=high capacity possible)
Auto Calibration
Select “yes” if, subsequently to a change of recipe, the
first dosing is to be made with reduced batch weight (calculated dosing time > 200 ms)
Select “no” if, subsequently to a change of recipe, the
first dosing is to be made without reduced batch weight.
UB Touch
Config 2
&
Recipe Calculation
Select type of recipe calculation:
Parts The sum of all components is irrelevant, all materials are equivalent, the control calculates automatically
the percentage of each component.
New material = 100
Materials from the dosing units “Regenerat“ are understood by the control as already dosed material. Raw material and additive together must add up to 100 %.
Material to be ground + new material = 100
The sum of all components must be 100 %.
Regrind Correction
Select the material correction in the case of faulty dosing:
None = no correction
Direkt = more material àmore new material,
the ratio material to be ground to new material remains
about the same.
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Invers = more material à less new material,
the batch weight remains about the same.
UB Touch
Host
&
Host Protocol
not active
This function is not active at present.
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&
UB Touch
I/O Test
&
Outputs
# 1 -6
Click dosing stations to open / close the dosing slide valve.
Scale
Click “scale” to close the weighing container.
Click “close” to open the weighing container.
M. Hop (= mixing hopper)
Click “M.H” to open the mixing chamber.
Click “open” to close the mixing chamber.
M. Mot (= mixer motor)
Click “M.Mot” to start the mixer.
Click “on” to stop the mixer .
Alarm
Click “alarm” to test the alarm relay. If a signal light is connected (optionally) it will flash.
Res1/ Res2
These functions are not active at present.
Inputs
# 1 -6
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The display is green when the probe in the dosing station
is covered with material (= status: closed).
M.Hop (= mixing hopper)
DThe display is green when the probe in the mixing hopper is covered with material (= status: closed).
Leve (= level probe)
The display is green when the probe under the mixing
hopper is covered with material (= status: closed).
Sec. (security switch)
The display is green when the safety chain (e.g. door
switch) is not interrupted.
Scale
Value measured by scale
Res1/ Res2/Res3
These functions are not active at present.
UB Touch
Address
&
Station type
Select station type of dosing unit:
Ds = dosing unit small
Dm = dosing unit medium
Dl = dosing unit large
Dx = dosing unit extra
dM = auger filler
Sensor
Select “Y” if there is a probe.
Select “N” if there is no probe.
Address
Assign the addresses A1-A6 to the components 1-6.
Reaction time [ms]
Enter reaction time in ms.
Test
Click “test” to open the slide valve / to start the auger filler.
During the reaction time 3 grains of material should
drop, repeat if necessary or adjust setting of reaction time.
Changed à Reset
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Reset system if data have been changed.
UB Touch
Password
&
This function is password-protected (password level 1 - 4).
The entry of a password prevents unauthorised persons from having access to the data entered into
the control system. Important data can then be entered or modified only after the password has been
entered.
The control system differentiates between several password levels into which the data access is subdivided.
&
The higher the password level, the less possibility to change the data.
Level 5 = User 1, to change portions / percentages
Level 4 = User 2 , to change current recipe
Level 3 = Supervisor, to change recipes and configurations
Level 2 = Service, to change configuration parameters
Level 1 = Colortronic Service only
Entry “0”: Password not activated
F
Tell the password only to authorised persons.
User 1 (Level 5)
Change portions / percentages
User 2 (Level 4)
Change current recipe.
Supervisor (Level 3)
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Change recipe and configuration.
Service (Level 2)
Change basic settings and service parameters.
UB 75
12. Spare parts list
»
This chapter is intended exclusively to be used by trained personnel.
Other persons are not permitted to carry through modifications or repair
works of the device.
Designation
38301
Weighing bin, complete
38314
Threaded joint
38305
Flap of the weighing bin
38313
Short stroke cylinder
38302
Bearing front side
38303
Bearing motor side
38304
Door
84626
Magnet
38310
Lock
38307
Agitatorshaft
82997
Weighing cell
38309
Pneumatic turn-drive
84916
4/2 port directional control valve
85774
Filterpressure controller, complete
84627
Magnetic switch
38311
Red light sensor
38312
Coupling set
38316
Lid for material hopper
38321
Sliding plate
38322
Sightglass
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ID-No.
Spare parts list 12-1
UB 75
13. Accessories
o _____________________________________________
o _____________________________________________
o _____________________________________________
o _____________________________________________
o _____________________________________________
64.10-0268GB02 12/03
o _____________________________________________
Accessories 13-1

Operating Instructions Gravimetric Batch Blending System

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