Conair TrueBlend TB45-4 User manual

www.conairnet.com
USER GUIDE
UGB011-0207
TrueBlend™
Gravimetric Blender
Software Version V2.7
USER INSTRUCTIONS • About this operating manual • Warranty and liability • Layout of the manual • Meaning of safety
information Display conventions • Pictograms for safety and information Abbreviations • SAFETY • General • Designated
use • Sources of danger • Safety devices • Warning symbols on the unit • Information for the operator • Information for
operating and maintenance personnel • TECHNICAL SPECIFICATIONS • Manufacturer • Specifications • TRANSPORT AND
SETUP • Unpacking • Lifting • Setup • Positioning controller • Making connections • Stowing discharge chute
STRUCTURE AND FUNCTION • Structure of the unit • Brief description of the functional units • Layout of the material
hoppers • Operating modes • Gravimetric mode • Volumetric mode • Combined mode • COMMISSIONING • OPERATION
Switching on • Menu structure • Navigation • Starting and stopping the metering and mixing process • Switching off
Logging in/logging out • Commissioning • Mixing process • Component setup • GRAVICOLOR Setup • Working with recipes
Changing material for a component (also valid for all other components) • Checking total throughout • Creating reports
Corporate Office: 412.312.6000 | Instant Access 24/7 (Parts and Service): 800.458.1960 | Parts and Services: 814.437.6861
WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at [e-mail] or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.

Copyright
© 2007 Conair
The information contained in these operating instructions, including any transla-
tion thereof, is the property of Conair and may not be reproduced or transmitted in
any form or by any means (electronic, mechanical, photocopying, recording or
otherwise, nor stored in any retrieval system of any nature for any purpose) with-
out the express written authority of Conair
•To every person concerned with commissioning of the devices/systems it is
recommended to read thoroughly these operating instructions.
Conair accepts no responsibility or liability for damage or malfunction of the
equipment arising from non-observance of these operating instructions.
•To avoid errors and to ensure trouble-free operation, it is essential that
these operating instructions are read and understood by all personnel who
are to use the equipment.
•Should you have problems or difficulties with the equipment, please contact
your local Conair partner (see list attached).
•These operating instructions only apply to the equipment described below.
Manufacturing address:
The Conair Group, Inc.
455 Allegheny Blvd.
Franklin, PA 16323
USA
Phone: [phone]
Fax: [phone]
http://www.conairnet.com/
Conair Headquarters:
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
USA
CE
07/2004

Contents TrueBlend™
2 Edition: February 2007
Contents
1.0 User instructions................................................................................................ 7
1.1 About this operating manual.................................................................................... 7
1.2 Layout of the manual............................................................................................... 8
1.3 Meaning of safety information ................................................................................. 9
1.4 Pictograms for safety and information................................................................... 10
1.5 Abbreviations......................................................................................................... 10
2.0 Safety ................................................................................................................ 11
2.1 General.................................................................................................................. 11
2.2 Safety Hazards...................................................................................................... 11
2.3 Safety Features..................................................................................................... 12
2.4 Designated use ..................................................................................................... 12
2.5 Sources of danger................................................................................................. 14
2.6 Safety devices....................................................................................................... 17
2.6.1 Position of safety devices........................................................................... 17
2.6.2 Detachable Material Hopper Procedure..................................................... 18
2.7 Warning symbols on the unit................................................................................. 19
2.7.1 Position of warning symbols on the unit..................................................... 19
2.7.2 Meaning of warning symbols on the unit.................................................... 20
2.8 Information for the operator................................................................................... 20
2.8.1 Qualifications of personnel......................................................................... 20
2.9 Information for operating and maintenance personnel.......................................... 21
3.0 Technical specifications.................................................................................. 22
4.0 Transport and setup ........................................................................................ 31
4.1 Unpacking ............................................................................................................. 31
4.2 Lifting..................................................................................................................... 31
4.3 Setup..................................................................................................................... 32
4.4 Positioning controller ............................................................................................. 32
4.5 Making connections............................................................................................... 33
4.5.1 Compressed air connection ....................................................................... 33

TrueBlend™ Contents
Edition: February 2007 3
4.5.2 Electrical connection .................................................................................. 33
4.5.3 Hopper loader connection (option)............................................................. 34
5.0 Structure and function .....................................................................................35
5.1 Structure of the unit............................................................................................... 35
5.2 Brief description of the functional units (Item numbers refer to diagram on
previous page)................................................................................................................ 36
5.3 Layout of the material hoppers ............................................................................. 36
5.3.1 For four component blenders..................................................................... 37
5.3.2 For six component blenders....................................................................... 37
5.4 Operating modes .................................................................................................. 38
5.4.1 Gravimetric mode....................................................................................... 39
5.4.2 Volumetric mode ........................................................................................ 39
5.4.3 Combined mode......................................................................................... 39
6.0 Start-up..............................................................................................................40
7.0 Operation...........................................................................................................40
7.1 Switching on.......................................................................................................... 40
7.1.1 Switch on main switch................................................................................ 40
7.2 Menu structure ...................................................................................................... 41
7.3 Navigation ............................................................................................................. 41
7.3.1 Explanation of the navigation buttons........................................................ 42
7.3.2 Explanation of keypad screens.................................................................. 45
7.3.3 Explanation of additional screen icons....................................................... 46
7.4 Starting and stopping the blending process.......................................................... 47
7.4.1 Starting blender process (with set values or factory setting) ..................... 47
7.4.2 Stopping the blending process................................................................... 47
7.4.3 Restarting after EMERGENCY STOP ....................................................... 47
7.5 Turning off the power ............................................................................................ 48
7.5.1 Stopping the blender at the end of a cycle................................................. 48
7.5.2 Switching off in emergency........................................................................ 48
7.6 Logging in/logging out........................................................................................... 49
7.6.1 User levels and password input (for service users only!) (Level 3)........ 49
7.6.2 Changing password (for service users only!) (Level 3).......................... 49
7.6.3 Auto logout (for service users only!) (Level 3) ....................................... 50
7.6.4 Parameters/Global Reset (for service users only!) (Level 3) ................. 51

Contents TrueBlend™
4 Edition: February 2007
7.7 Start-up.................................................................................................................. 52
7.7.1 Checking functions in manual mode .......................................................... 52
7.7.2 Calibrating .................................................................................................. 56
7.7.3 Input TrueBlend Model/Name (for service users only!) (Level 3)........... 61
7.7.4 Input TrueBlend name................................................................................ 62
7.7.5 Activating Batch Setting ............................................................................. 62
7.8 Blending process................................................................................................... 65
7.8.1 Assigning components – factory default setting......................................... 65
7.8.2 Example of a mixing process ..................................................................... 67
7.8.3 Typical dispense cycle based (7.8.2) settings............................................ 68
7.9 Component setup.................................................................................................. 69
7.9.1 Input of material percentages..................................................................... 70
7.9.2 Input of Material type.................................................................................. 70
7.9.3 Input Alarm mode....................................................................................... 71
7.9.4 Input Dosing retries .................................................................................... 71
7.10 TrueBlend Setup ................................................................................................... 72
7.10.1 Setting Operating mode ............................................................................. 72
7.10.2 Setting Weigh Bin Batch weight ................................................................. 73
7.10.3 Setting Mixing time..................................................................................... 74
7.10.4 Setting the Interval time ............................................................................. 74
7.10.5 Setting Damping......................................................................................... 74
7.10.6 Advanced Operation Settings (Password level 3 only) .............................. 75
7.11 Working with recipes ............................................................................................. 79
7.11.1 Calling recipe status................................................................................... 79
7.11.2 Assigning an order number ........................................................................ 79
7.11.3 Save a new recipe...................................................................................... 80
7.11.4 Naming a recipe ......................................................................................... 80
7.11.5 Deleting a recipe ........................................................................................ 81
7.11.6 Load/view a recipe ..................................................................................... 82
7.12 Changing material in a blender component (also valid for all other components). 83
7.12.1 Detachable Material Hopper Procedure..................................................... 83
7.12.2 Manual cleaning: ........................................................................................ 84
7.12.3 Clean-out with optional drain chute with safety interlock ........................... 86
7.13 Checking total throughput ..................................................................................... 88
7.14 Creating reports..................................................................................................... 89
7.14.1 Reports for batches, shifts, recipes and scales.......................................... 89
7.14.2 Report generator – TrueBlend Reports...................................................... 90
7.14.3 Operation ................................................................................................... 91
7.15 System setup......................................................................................................... 95
7.16 Panel setup ........................................................................................................... 96
7.17 System info............................................................................................................ 97

TrueBlend™ Contents
Edition: February 2007 5
7.18 Maintenance ......................................................................................................... 98
7.19 Hopper loaders (Optional)................................................................................... 100
7.19.1 Go to Material loading (conveying) overview screen ............................... 100
7.19.2 Switching on hopper loaders.................................................................... 100
7.19.3 Changes to Loader Screen...................................................................... 102
7.19.4 Loader Alarm Settings ............................................................................. 102
7.19.5 Settings.................................................................................................... 103
8.0 Alarm messages and troubleshooting..........................................................108
8.1 Signaling alarm message.................................................................................... 108
8.2 Handling alarm messages .................................................................................. 108
8.3 Deciphering Alarm Messages ............................................................................. 109
8.4 Alarm messages and correction ......................................................................... 109
8.5 Troubleshooting/Mechanics ................................................................................ 114
8.6 Diagnostic Overview Screens ............................................................................. 115
9.0 Maintenance and repair..................................................................................117
9.1 Safety.................................................................................................................. 117
9.1.1 Qualifications of personnel....................................................................... 117
9.1.2 Safety equipment ..................................................................................... 117
9.1.3 Safety equipment ..................................................................................... 117
9.2 Before starting work ............................................................................................ 118
9.2.1 Switch off unit/disconnect from compressed air supply ........................... 118
9.3 Inspections.......................................................................................................... 118
9.3.1 Checking EMERGENCY STOP function ................................................. 118
9.3.2 Testing safety interlock switch ................................................................. 118
9.3.3 Test the safety interlock switch as described in 7.7.1
Checking functions in manual mode. .................................................................. 118
9.4 Mixing chamber instructions ............................................................................... 119
9.5 Maintenance work............................................................................................... 120
9.5.1 Annual maintenance work........................................................................ 121
9.6 Repair work......................................................................................................... 123
9.6.1 Calibrate/adjust a sensor with no material present.................................. 123
9.6.2 Replacing pneumatic cylinder on vertical dispense valve assembly........ 126
9.6.3 Load Cell Removal and Installation for Trueblend models,
TB045 and TB100............................................................................................... 127
9.6.4 Load Cell Removal and Installation for Trueblend models,
TB250, TB500 and TB900 .................................................................................. 129
9.6.5 Replacing controller ................................................................................. 132

Contents TrueBlend™
6 Edition: February 2007
9.7 Cleaning .............................................................................................................. 133
9.7.1 Cleaning material hopper and mixing chamber........................................ 133
10.0 Decommissioning and disposal........................................................... 134
10.1 Decommissioning the unit ................................................................................... 134
10.2 Disposing of unit parts......................................................................................... 134
11.0 Appendix ................................................................................................ 135
11.1 Menu structure .................................................................................................... 135
11.1.1 Operating levels/password level .............................................................. 135
11.1.2 Menu overview/dosing unit....................................................................... 136
11.1.3 Menu overview/conveying........................................................................ 137
11.1.4 System settings menu.............................................................................. 138
11.1.5 Unit settings menu ................................................................................... 139
11.1.6 Conveyor settings menu .......................................................................... 140
12.0 Appendix: Addendum for Retrofit Blenders........................................ 141
12.1 Retrofit Control Blender Start up Procedures...................................................... 141
13.0 Appendix ................................................................................................ 143
13.1 Blow off installation instruction sheet .................................................................. 143
14.0 Appendix ................................................................................................ 145
14.1 Replacing the TrueBlend Touch Screen Control................................................. 145

TrueBlend™ User Instructions
Edition: February 2007 7
1.0 User instructions
1.1 About this operating manual
This operating manual is a component of the TrueBlend Gravimetric blender.
It contains important instructions on the correct operative and maintenance of the
unit. Follow these instructions to avoid dangers, to prevent repair expenses and
downtime and to increase the service life of the unit.
The manual must be kept for referral with the unit at its place of use. The manual
must also accompany the unit if it is rented or sold.
It is directed to people who operate and repair the unit and must be read, under-
stood and used by every person who is responsible for the following work with the
unit:
•Transport and setup,
•Operation,
•Maintenance and repair,
•Correction of faults,
•Decommissioning and disposal.
Take particular note of
•the chapter on,
•the warning notes in the various chapters.

User Instructions TrueBlend™
8 Edition: February 2007
1.2 Layout of the manual
This manual is classified into several main parts:
•User information,
•Safety,
•Technical specifications,
•Transport and setup,
•Structure and function,
•Operation,
•Maintenance and repair,
•Decommissioning and disposal,
•Appendix (menu structure).

TrueBlend™ User Instructions
Edition: February 2007 9
1.3 Meaning of safety information
Safety instructions are placed before the work steps. Read the safety instructions
carefully before carrying out the subsequent operation.
If safety instructions are not followed, serious personal injury - possibly with fatal
results - and property and environmental damage may occur!
The safety instruction in this operating manual are indicated with a symbol. The
symbol contains a signal word indicating how serious the danger is.
DANGER!
A symbol with the word "DANGER" warns of an imminent danger to the
health and life of persons.
If these safety instructions are not observed serious or even fatal injuries
will be caused.
ÎAlways observe the directions for avoiding such dangers.
WARNING!
A symbol with the word "WARNING" warns of a possible dangerous situa-
tion for the health and life of persons.
If these safety instructions are not observed serious or even fatal injuries
may be caused.
ÎAlways observe the directions for avoiding such dangers.
CAUTION!
A symbol with the word "CAUTION" warns of a possible dangerous situa-
tion for the health and life of persons or of property and environmental dam-
age.
If these safety instruction are not observed injury or property and environ-
mental damage may occur.
ÎAlways observe the directions for avoiding such dangers.

User Instructions TrueBlend™
10 Edition: February 2007
1.4 Pictograms for safety and information
In this operating manual you will find sections of text that a re identified by picto-
grams. The meaning of the pictograms is described below.
Pictogram for general identification of hazards. This pictogram occurs in con-
nection with safety instructions (see 1.3 Meaning of safety information).
Pictogram for hand injury. This pictogram occurs in connection with safety
instructions (see 1.3 Meaning of safety information).
Pictogram for electric shock. This pictogram occurs in connection with safety
instructions (see 1.3 Meaning of safety information).
Pictogram information for identification of important instructions, additional
information and tips.
Pictogram for safety gloves that warns you to wear safety gloves.
1.5 Abbreviations
The following terms and abbreviations are used in this operating manual (in al-
phabetical order):
Abbreviation Meaning
CAN Controller Area Network
E-motor Electric motor
LED Light-emitting diode
PU Polyurethane

TrueBlend™ Safety
Edition: February 2007 11
2.0 Safety
2.1 General
This chapter contains basic safety instructions for working with the gravimetric
batch blending unit.
Observe all the instructions for the operation and maintenance of the unit in this
chapter.
In addition, observe the warning notices that are placed before the action direc-
tions where the operating steps are described.
2.2 Safety Hazards
MIX BLADES
Mix blades are driven with substantial torque.
NEVER place your hand in the mix chamber unless power is completely dis-
connected.
SERIOUS INJURY may result.
ADDITIONAL MIX BLADE HAZARD
Over time, mix blades may become RAZOR SHARP.
Always be careful when TOUCHING or CLEANING these blades.
Check for sharp edges frequently.
Replace blade if a hazard exists.
VERTICAL VALVES
Vertical valves in hoppers SLAM CLOSED without warning.
They will injure your fingers.
ALWAYS keep fingers clear valve openings.
NEVER use your fingers to clear an obstruction.
NEVER use your fingers to move a sticking valve.

Safety TrueBlend™
12 Edition: February 2007
SLIDE GATE/MIX CHAMBER
NEVER use your fingers to move a sticking slide gate under the mix cham-
ber.
2.3 Safety Features
SAFETY INTERLOCK SWITCH
The ACCESS DOOR is equipped with a safety interlock switch that prevents
the mix motor from running and the slide valves from operating.
DO NOT defeat this safety switch
HOPPER FINGER GUARDS
Finger guards are fitted into each hopper compartment.
DO NOT reach through these guards.
DO NOT use your fingers to clear an obstruction below these guards.
DO NOT remove these guards.
2.4 Designated use
The TrueBlend gravimetric blender must be used exclusively for metering and
mixing free-flowing1plastic granulate and additives. A total of four different mate-
rials can be metered and mixed in the TB 45 and TB 100 models. Other models
for up to six different materials are available including the: TB 250, 500 and 900
model series.
The following must not be metered and mixed:
•Foods of all types (the unit does not meet the hygienic standards),
•Highly abrasive materials, such as stones, sand (increased wear of unit
components),
•Poorly free-flowing, sticky materials (materials only flow poorly, airtight seal
by the pneumatic cylinder is adversely affected),
•Liquids and powders (airtight seal by the pneumatic cylinder is not possi-
ble).
1as per DIN ISO 3435

TrueBlend™ Safety
Edition: February 2007 13
Do not make any changes to the unit. Any changes may adversely affect the
safety of the unit.
Designated use includes following this operating manual and following the speci-
fied maintenance intervals and conditions.
NOTE
Please contact Conair if you have any questions about the designated use of
the unit.

Safety TrueBlend™
14 Edition: February 2007
2.5 Sources of danger
The unit is manufactured to comply with the state of the art in technology and the
generally accepted rules of safety engineering. However, operation of the unit
may give rise to dangers for life and limb of the operator or third parties or dam-
age to the unit or other property.
The unit has four sources of danger, which are shown in the figure below:
Fig. 1: Sources of danger
[1] Electrical system/power cabinet
[2] Pneumatic material seal at the outlet of the pneumatically operated vertical
valves
[3] Agitator in mixing chamber
[4] Pneumatic seal at the discharge slide gate

TrueBlend™ Safety
Edition: February 2007 15
The sources of danger and the consequences are shown in more detail below:
Danger source Consequences
Electrical system Fatal injury by electric shock!
High voltages can cause life-threatening currents
in the body and electric shock.
ÎAllow only trained and qualified electrical tech-
nicians to work on the electrical system.
ÎBefore any electrical work disconnect the unit
from the power supply and lock to prevent un-
authorized persons switching it on.
Pneumatic seal on
supply hoppers
Danger of injury by moving parts!
Vertically moving pneumatic cylinders can cause
crushing, impact and shearing injuries.
ÎDo not reach into the pneumatic seal of the
supply hopper during normal operation and
during manual operation.
Mixer Danger of injury by moving parts!
Rotating mixing blades can catch body parts and
pull them in and cause life-threatening crushing,
shearing and bone fracture injuries.
The edges of the mixing blades can be as sharp
as knives after extended operation.
ÎNever reach into the mixing chamber while the
mixer is rotating.
ÎDo not extend any objects into the movement
range of the mixer.
ÎDo not disable the safety interlock switch.
ÎWear gloves when touching or cleaning the
stationary mixer.

Safety TrueBlend™
16 Edition: February 2007
Danger source Consequences
Pneumatic seal on the
discharge slide gate2at
bottom of mix chamber
Danger of injury by moving parts!
Horizontally moving pneumatic cylinders can
cause crushing, impact and shearing injuries and
bone fractures.
ÎDo not reach into the pneumatic discharge
slide gate during normal operation and during
manual operation.
2The pneumatic discharge slide gate is not installed if a manual slide gate is installed and the unit is
mounted directly on the injection molding machine.

TrueBlend™ Safety
Edition: February 2007 17
2.6 Safety devices
Safety devices protect your health and your life.
Do not operate the unit without effective safety devices.
WARNING!
DANGER OF INJURY!
The operator runs the risk of injury if the safety devices are not operating cor-
rectly.
ÎCheck that the safety devices function correctly after work has finished
(see 7.7.1 Testing the mix chamber safety interlock switch).
2.6.1 Position of safety devices
Fig. 2: Safety devices
[1] Finger guard
[2] Safety interlock switch (Mix chamber door)
[3] Main switch (=EMERGENCY STOP)
[4] Padlock
[5} Alarm beacon
[6] Alarm horn
Electrical System/Power Cabinet

Safety TrueBlend™
18 Edition: February 2007
Safety device Safety function
Safety guard Prevents injury by crushing and impact at the pneu-
matic cylinder of the supply hopper.
Safety interlock
switch
Stops the mixer motor when the main door is opened.
EMERGENCY STOP
switch
Stops all movement of the machine.
Padlock Locks the switch to prevent unauthorized persons
switching it on.
2.6.2 Detachable Material Hopper Procedure
NOTE
Detachable material hopper for TB45 (4 bins) TB100 (2 bins) and
TB250R-4 (2 bins) models.
All detachable material hoppers on the above referenced models are held in place
with a captive retainer (screw) held in the hopper support frame. The retainer
stabilizes the detachable hopper when mounted in the blender support frame from
forces exerted on the hopper by resin weight and various types of automatic
loading/receiving device(s) during normal vibration from the process. There is a
separate retainer for each detachable hopper.
When removing any of these detachable hoppers for cleaning or material
changeover; first, remove the automatic loading/receiving device; then use the
proper hex head socket or screwdriver and back out the captive retainer. Hopper
can then be removed.
Upon re-insertion of the detachable hopper, it is very important to re-anchor
the respective hopper(s) using the captive retainer to provide stability
during normal operation of the blender. Once the hoppers have been placed
and anchored, the respective loading / receiving devices can be mounted.