VOLUMETRIC BLENDING SYSTEM OPERATION MANUAL

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1 VOLUMETRIC BLENDING SYSTEM OPERATION MANUAL E. MAIN ST. MARSHALL, IL PHONE: FAX: WEB SITE: 1

2 OPENING SCREEN The OPENING SCREEN is the screen that the PLC system boots up to if ever a power cycle was to occur. From here you can navigate to any location in the system. At the bottom of this screen and all other screens is the menu bar. Most of the operations will be performed through the SYSTEM MENU and VALVE MENU buttons. A description of each button will follow later in the manual. 2

3 SYSTEM MENU button The SYSTEM MENU button groups system related screens 3

4 DISPLAY SETTINGS Here you can adjust the display brightness, activate a screen saver and set the system time and date. For brightness control you would just arrow up or arrow down. The screen saver is activated by pressing its button. The time and date can be set by pressing the SET TIME/DATE button and follow the format shown. 4

5 BLEND ENTRY Blend Entry begins the process of running a blend. Here you would enter the weight of each chemical in each hopper. The name of each chemical is listed above the hopper weight entry button. Entering actual weight per each hopper would be the method used when not running a saved ratio blend. After you enter in all desired weights for each chemical, you would then press the RUN BLEND button. Any alarms that may occur will appear towards the bottom of the screen. For instance if weight is entered for a hopper and that hopper does not have its VOLUME CONSTANT, BULK DENSITY, or VALVE DELAY set, an alarm will appear. These three characteristics must be set before running a hopper. The numeric values shown at each hopper is the valve RPM speed at which the valve will run. As the weight changes for each valve, these values may also change. 75RPM is the fastest and 8RPM is the slowest speed a valve can start at. 5

6 RUN BLEND The RUN BLEND screen can only be accessed through the Blend Entry screen when weight has been entered in one or more valves. Here only the hopper or hoppers with blend weight will appear. Also the run-time is also calculated and displayed. The color scheme for each valve is as follows: green indicated the valve is in DW mode, Silver indicates volumetric mode, and orange indicates impregnation mode. Once the run-time is displayed and the START button, the blend will start when the operator presses the START button. After a blend is started, this same button becomes the PAUSE button for pausing blends. Then START again to re-start. After a blend has started a CANCEL button appears which can be used to cancel a blend completely forcing. 6

7 SPOUT LOCATION The SPOUT LOCATION screen can also be accessed through the RUN BLEND screen. Here you just select which spout you want your blend to travel through. The current location of the SPOUT is shown in the top right corner. The SP1,SP2 names can be changed to the users liking of 14 characters or less. 7

8 LOADOUT DELAYS The LOADOUT DELAY should be set to a high enough number so at the end of a blend all product has been cleaned out of the conveyance systems. This would include all conveying sections after the under bin. The delay time is in seconds. 8

9 I/O SCREEN The I/O SCREEN is mainly used for troubleshooting and/or maintenance. Here you can view all input and output status. 9

10 VALVE MENU button The VALVE MENU button groups valve related screens. 10

11 VOLUME CONSTANT VOLUME CONSTANT screen is used to set the volume constant of each valve. In a DW system this value can be self adjusted or calibrated at the end of each blend for more precise weight loss accuracy. 11

12 BULK DENSITY Each chemical for each hopper should have its BULK DENSITY measured by the scale and the values can be input for each hopper using the Read from Scale button. 12

13 EMPTY HOPPERS EMPTY HOPPER screen is used for cleaning out a hopper in order to fill that hopper with a different chemical. There is no system feedback when emptying a hopper. Once you press the button the hopper will run until you press the button again to stop it. 13

14 VALVE DELAYS The value entered here for each DELAY VALVE is in seconds and should be a measured time of how long it takes for the product to get from one valve to the next valve in front of it. This run-time can be calculated or simply entered by using a stop watch. A DELAY VALUE cannot be equal to zero. If a zero is needed a value of.01 is sufficient. The VALVE DELAY time reference is the end of the under bin. This is referred to as the focal point. Start out by measuring the time the chemical of the last valve (closest to the focal point) takes to reach the focal point. After this then measure the time the chemical of the next valve back (second to last) takes to reach the last valve. Repeat this process until you reach the first valve. 14

15 VALVE TEXT ENTRY The chemical name that s in each hopper can be entered here and is used throughout the system. This name can be 14 characters or less and can be the same name that s in another hopper. 15

16 BINDICATORS BRIDGED INDICATOR The bridged indicator is right above the discharge of the rotary valve on the back. This sensor is to sense a bridged condition. As soon as this condition is detected, the system goes into an emergency shutdown condition. All rotary valves as well as the main auger will shut down immediately. This prevents the batch from being corrupted and maintains the integrity of the batch. To fix this condition, the operator must rap the side of the bin with a rubber mallet. When the bridge has been broken pressing the RESET ALARMS button can reset the Alarm. Once reset, the START button can be pressed to resume the batch cycle. ROTARY VALVE INDICATOR Each VFD is equipped with a relay that tells the system whether or not the VFD is running. If the VFD overloads, or shuts down for any reason, the system will stop. If this happens, turn off the VFD, wait for it to power down, then turn it back on to reset it. Following this, press the Reset Alarms button on the touch screen. Once reset, the START button can be pressed to resume the batch cycle. UNDER BIN AUGER INDICATOR The Under Bin auger is equipped with a Zero Speed switch, which senses if the auger is turning when the system is running. If for some reason the auger stops during a batch cycle, the system will go into an emergency shutdown. Once the problem has been corrected, and the Alarm has been reset on the main panel, the START button can be pressed to resume the batch cycle. LOAD OUT CONVEYOR INDICATOR The Load out Conveyor is equipped with a Zero Speed switch, which senses if the auger is turning when the system is running. If for some reason the Conveyor stops during a batch cycle, the system will go into an emergency shutdown. Once the problem has been corrected, and the Alarm has been reset on the main panel, the START button can be pressed to resume the batch cycle. 16

17 VALVE ALARMS An * denotes alarm will not stop a run or prevent a blend from being made ALARM DIAGNOSTIC SOLUTION Standard Alarms Hopper Bridged Low Level Hopper * Hopper x Valve Motion Blend Ratio is too rich Indicates that there is no material that is ready to be distributed by the valve. Material in hopper is below sensor level Valve is not turning One or more weights is too low or high Usually caused by an air pocket or clumped/stuck material to hopper or hopper has run empty. Fill hopper before it runs out of product Something is preventing valve from moving or is a VFD issue VFD's cannot turn valves slow enough to compensate for weight, adjust blend Emergency Stop Emergency Stop Button was pressed. Pull out E-stop and reset alarms BE Pressure Switch Spout is plugged Unplug the spout and reset alarms Bucket Elevator Zero Speed Underbin Zero Speed Loadout Zero Speed Zero speed switch detects no motion or not enough RPM's Make sure conveyor is running/running at required speed, make sure that Zero Speed Switch has not fallen out of calibration 17

18 12285 EAST MAIN STREET MARSHALL, IL VOLUMETRIC AND DW MANUAL SENSORS AND ADJUSTMENT PROCEDURES 18

19 Volumetric and DW Manual Sensors and Adjustment procedures 1. Sensor Adjustment a. Low Level (IF APPLICABLE) and Bridge Sensor To adjust the low level or bridge sensor, first, empty the hopper and verify that there is no build up of any kind on the sensor well. If there is it must be removed. Once this is done, use a small screwdriver to find the set point of the sensor. The set point of the sensor is found by rotating the adjustment screw in & out until you find the point that the red light on the sensor turns on and off. Tightening the adjustment screw should make the light come on, and loosening the screw should make it go off. Once the set point has been reached loosen the adjustment screw two full turns, once this is complete no further adjustment is necessary. Weekly maintenance should be performed on this sensor in the form of a visual inspection of the sensor well and cleaning of caked on product from it. Zero Speed Switch and Disc Zero speed switches are located on the tail roller of all conveyors, the boot of bucket elevators, and on the shaft of Augers. The Zero Speed Sensor is factory preset. No adjustments should have to be made after installation. When correctly installed the gray plastic sensor should be centered on the white line located around the pulser disc. The sensor face should be about 1/8 inch to ¼ inch from the face of the pulser disc. 19

20 Binful Switch If your Volumetric Blender has a Bucket Elevator transport system, then there will be a Binful pressure switch located in the Head of the Bucket Elevator. In the event that the Down spout on the Bucket Elevator becomes plugged and product backs into the head of the Bucket Elevator the Binful Pressure Switch will shut power off to the Leg and prevent it from running until the down spout can be emptied. There are no adjustments or calibrations for this sensor. Fig. 3 Routine Valve Maintenance The Volumetric valve (like any other equipment moving fertilizer) will require periodic cleaning. It is necessary to remove the cover and inspect the Volumetric Valve cups weekly in order to maintain an accurate blend system. 20

21 12285 EAST MAIN STREET MARSHALL, IL VFD SETUP INFORMATION 21

22 VFD Reset Information If a Frequency drive over loads or faults out for any reason, record the code displayed on the display of the drive, then shut off the circuit breaker located next to the frequency drive. Wait until the frequency drive powers down completely, this can take up to thirty seconds. Once power down is complete the breaker can be turned back on and the drive will reset itself. In the normal operating mode the drive should display 0.0 in the display and the run light should be on. As displayed in the picture. Note: When foreign matter is introduced into a volumetric valve (hammer, screwdriver, or 2x4) it is normal for the valve to overload, the above procedure should be used to reset the valve. No regular maintenance is required for the VFD or breaker, but it should be inspected weekly to make sure the fiberglass box is closed and latched, and that there are no air leaks allowing fertilizer to gain entry into the panel. VFD AMPERAGE SETTING 1) On the green terminals below the touch buttons, find a jumper wire that is tied to SD and going to either STF (forward) or STR (reverse). It will only be going to one of those two, as it determines motor direction. Disconnect STF or STR. 2) Press the Mode button once. The display should show P. (number) 3) Use the scroll wheel to go to P79. Press set. 4) Use the scroll wheel to go from 3 to 0. Press set To Change the Amperage: 1) From P79, use the scroll wheel to navigate to P9 2) Press set 3) Use the scroll wheel to set to desired amps 4) Press set 22

23 5) Scroll back to P79 6) Press Set 7) Change from 0 to 3 8) Press Set 9) Press mode button twice. The display should read ) Turn off the VFD via the breaker. 11) Reconnect STF or STR 12) Turn VFD back on VFD MANUAL RUN 1) On the green terminals below the touch buttons, find a jumper wire that is tied to SD and going to either STF (forward) or STR (reverse). It will only be going to one of those two, as it determines motor direction. Disconnect STF or STR. 2) Press the Mode button once. The display should show P. (number) 4) Use the scroll wheel to go to P79. Press set. 5) Use the school wheel to set the number to 0. (From 3) Press set. 6) Press Mode twice until display reads ) Use the scroll wheel to dial in the speed of the valve (5.0 being the slowest, 55.0 being the fastest) 8) Press set 9) Display should flash desired speed and F (Forward) then return to ) Press the Run key to begin turning the valve at requested speed. 11) Press Stop when finished. If running the wrong direction: -Press the Mode button once. The display should show P. (number) -Use the scroll wheel to navigate to P40. Press Set -Use the scroll wheel to change number to 1 (From 0) -Press set -Press Mode twice and display should read Press the Run button, valve turn should be reversed. When finished manually running: - Press the Mode button once. The display should show P. (number) - Using the Scroll Wheel, navigate to P79. Press Set -Change number from 0 to 3. Press Set -Press mode button twice until display reads Turn off the VFD -Reconnect jumper STF or STR 23

24 -Turn on VFD. VFD COMPLETE RESET 1) On the green terminals below the touch buttons, find a jumper wire that is tied to SD and going to either STF (forward) or STR (reverse). It will only be going to one of those two, as it determines motor direction. Disconnect STF or STR. 2) Press the Mode button once. The display should show P. (number) 3) Turn Scroll wheel left from P0 until the display reads ALLC 4) Press set 5) Change value from 0 to 1 6) Press set 7) Power down VFD 8) After 10 seconds, power up VFD. 9) Check the lights above the touch buttons. There are two lights labeled PU and EXT. Press the PU/EXT button once if the light is not on PU. 10) Press the Mode button once. The display should show P. (number) 11) Use the scroll wheel to go to P7. Press set. 12) Use the scroll wheel to set the number to.8. (From 5) Press set. 13) Use the scroll wheel to go to P8. Press set. 14) Use the scroll wheel to set the number to.8. (From 5) Press set. 15) Use the scroll wheel to go to P22. Press set. 16) Use the scroll wheel to set the number to 175. Press set. 17) Use the scroll wheel to go to P71. Press set. 18) Use the scroll wheel to set the number to 13. Press set. 19) Use the scroll wheel to set the number to P80. Press set. 20) Use the scroll wheel to set the number to number 1.5 (2HP Motor) or 2.2 (3HP Motor). Press set. 21) Use the scroll wheel to go to P83. Press set. 22) Use the scroll wheel to set the number to the amount of voltage supplied (240, 380, 415, 480). Press set. 23) Use the scroll wheel to go to P156. Press set. 24) Use the scroll wheel to set the number to 16. Press set. 25) Use the scroll wheel to go to P157. Press set. 26) Use the scroll wheel to set the number to 2. Press set. 27) Use the scroll wheel to go to P 180. Press set. 28) Use the scroll wheel to set the number to 4. (From 0) Press set. ******Only For Systems with wires in terminals A and C on the VFD****** 29) Use the scroll wheel to go to P192 30) Use the scroll wheel to set the number to 0. (From 99). Press set ***************************************************************** 31) Use the scroll wheel to go to P96. Press set. 32) Use the scroll wheel to set the number to 1. Press set. 33) Press mode button twice. There should be a 1 on the screen. Press Run. The number should change to 2 while the drive auto tunes. When the display reads 3, press the stop button. The drive is now tuned. 24

25 34) Press Mode button once. The display should read P96 still. 35) Use the scroll wheel to go to P79. Press set. 36) Use the scroll wheel to set the number to 3. Press set. 37) Turn VFD Power off. 38) Reconnect the wire to either STF or STR. 40) Turn VFD power on. 41) VFD setup complete. 25

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