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This manual is out-of-date and is provided only for its technical information, data and capacities.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than those contained in this out-of-date manual.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).