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Sterling A0567659 - page 1
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Sterling A0567659 - page 2
Page 2 of 118 SGB Batch Blender with Mitsubishi Controller Model # Serial # Write down your Blender ________________ ________________ serial numbers here _____________ _____________ for future reference ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ ___________ ...
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Sterling A0567659 - page 3
SGB Batch Blender with Mitsubishi Controller Page 3 of 118 Table of Contents Table of Contents ......................................................................................... 3 Safety Considerations .................................................................................. 5 Annex B Info rmation ................................... ...
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Sterling A0567659 - page 4
Page 4 of 118 SGB Batch Blender with Mitsubishi Controller Table of Contents 5 Operation ........................................................................................... 47 5-1 SGB Blender Sequenc e of Oper ation .......................................... 47 5-2 Quick Star t Procedur e .................................................... ...
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Sterling A0567659 - page 5
SGB Batch Blender with Mitsubishi Controller Pa ge 5 of 118 Safety Considerations Sterling equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining ...
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Sterling A0567659 - page 6
Page 6 of 118 SGB Batch Blender with Mitsubishi Controller Sterling “SGB-E” Series Blenders This blender is manufactured by ACS, In c. at the ACS-Wood Dale facility: ACS, Inc. 801 AEC Drive Wood Dale, IL 60191 Phone: 630.595.1060 Fax: 630.595.6641 The equipment is distributed in Europe by our European facility : ACS-EUROPE Daniels Industrial Es ...
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Sterling A0567659 - page 7
SGB Batch Blender with Mitsubishi Controller Pa ge 7 of 118 Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity ...
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Sterling A0567659 - page 8
Page 8 of 118 SGB Batch Blender with Mitsubishi Controller 1 General Information 1-1 Introduction We are pleased to supply Sterling auxilia ry equipment for your facility. We manufacture a complete line of auxiliary equ ipment to satisfy all of your material handling, process cooling, scrap recl aim, size reduction, and automation requirements. Ple ...
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Sterling A0567659 - page 9
SGB Batch Blender with Mitsubishi Controller Pa ge 9 of 118 1-5 Necessary Documents The documents listed below are necessary for proper installation, operation and maintenance of SGB Series Gravimet ric Batch Blenders. You can obtain additional copies from the Service D epartment at Sterling or ACS Europe. Make sure that appropriate personnel get f ...
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Sterling A0567659 - page 10
Page 10 of 118 SGB Batch Blender with Mitsubishi Controller 1-8 “SGB” Series Weigh Blender Mechanical Features SGB Slide Gate Blender • Efficient Opti-Mixer ® and “HC” mixer desig ns promote homogeneity • Exclusive diamond design slide gate metering assemblies meter a large range for free flowing pellet materials • Slide gate stroke ...
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Sterling A0567659 - page 11
SGB Batch Blender with Mitsubishi Controller Pa ge 11 of 118 1-9 “SGB” Series Weigh Blender with Mitsubishi Touch- Screen Control Features • LCD touch-screen interface display oper ator control panel with 8’ cable • Target vs. actual set point verification • Inventory accumulation for all ingredients • Audible and visual alarms • Au ...
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Sterling A0567659 - page 12
Page 12 of 118 SGB Batch Blender with Mitsubishi Controller 1-10 SGB (-E) Series Specifications SGB Series Specifications SGB-450 SGB-900 SGB-2500 SGB-4 000 SGB-5000 Number of materials blended 4 2 to 6 2 to 5 Slide gate (adjustable, in (mm)) squar e 2 (50) 2.5 (63) 3 (76) 4 (101) Supply hopper capacity, ft³ (l) 0.75 (21) 1 (28) 1.5 (42) 2 (56) We ...
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Sterling A0567659 - page 13
SGB Batch Blender with Mitsubishi Controller Pa ge 13 of 118 1-11 Model SGB Blender System Component Description This section describes the various co mponents of the blending system. The SGB blending system is made up of the following components: 1-11-1 Material Supply Hoppers 1-11-2 Slide Gate Metering Assemblies 1-11-3 Weigh Hopper 1-11-4 Weigh ...
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Sterling A0567659 - page 14
Page 14 of 118 SGB Batch Blender with Mitsubishi Controller 1-11-1 Material Supply Hoppers The material supply hoppers are loca ted on top of the blender frame. These hoppers store a supply of mate rial for the individual metering devices. They are sized based on t he total throughput of the blender. The SGB blending system does not include any lev ...
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Sterling A0567659 - page 15
SGB Batch Blender with Mitsubishi Controller Pa ge 15 of 118 1-11-2 Slide Gate Metering Assemblies Air operated slide gates are provided to meter the majo rity of pellet ingredients on the SGB blender. Important! The metering range assumes 1 / 8 ” diameter free-flowing plastic pellets weighing approximately 35 lb s./cu. ft. This is meant to be an ...
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Sterling A0567659 - page 16
Page 16 of 118 SGB Batch Blender with Mitsubishi Controller Each of the diamond gate air cylinders is actuated by a solenoid valve, which are controlled by the blender. When the solenoid valve is energized, it opens the metering valve cylinder. When the solenoid valve is de-energized, it closes the metering valve cylinder. If the power is interrupt ...
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Sterling A0567659 - page 17
SGB Batch Blender with Mitsubishi Controller Pa ge 17 of 118 1-11-3 Weigh Hopper The weigh hopper on the SGB blender is used to weigh each batch of material, and includes an air-operated discharge valve. After the batch is weighed and the level sensor in t he lower mix section is uncovered, the valve will open and discharge the batch into the mixer ...
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Sterling A0567659 - page 18
Page 18 of 118 SGB Batch Blender with Mitsubishi Controller 1-11-4 Weigh Hopper Discharge Valve The weigh hopper discharge valve holds the material until it is dumped into the mixing section. The cylinder is actuated by a solenoid in the valve stack on the rear of the blender. In looking at the pneumatic circuit, you can see that the air regulator ...
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Sterling A0567659 - page 19
SGB Batch Blender with Mitsubishi Controller Pa ge 19 of 118 1-11-5 Mix Chamber All of the Sterling batch blenders are equipped with an integral mix chamber. The mix chamber holds mult iple batches of material so any variations in a batch are averaged over time. 1-11-5-1 Opti-Mixer™ The Opti-mixer™ is designed to provide bi-directional mixing a ...
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Sterling A0567659 - page 20
Page 20 of 118 SGB Batch Blender with Mitsubishi Controller Typical Setup Screens ...
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Sterling A0567659 - page 21
SGB Batch Blender with Mitsubishi Controller Pa ge 21 of 118 Typical Operator Screens ...
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Sterling A0567659 - page 22
Page 22 of 118 SGB Batch Blender with Mitsubishi Controller Note: The touch-screen panel display on your unit may be slightly different than shown. ...
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Sterling A0567659 - page 23
SGB Batch Blender with Mitsubishi Controller Pa ge 23 of 118 1-12 Pneumatic Slide Gate Below Mixer (Optional) The SGB blending system c an be equipped with an optional pneumatic slide gate below the mixing chamber. The gate is us ed in applications when the blender is mounted above a large hopper, or for gaylord filling, etc. Th is gate holds the m ...
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Sterling A0567659 - page 24
Page 24 of 118 SGB Batch Blender with Mitsubishi Controller Safety 2 2-1 Work Rules Install, operate, and maintain this equi pment according to applicable work and safety codes for your location. This includes OSHA, CE, NEC, CSA, SPI, and many other local, national, and internati onal regulations. Obey these specific work rules: Read and follow ...
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Sterling A0567659 - page 25
SGB Batch Blender with Mitsubishi Controller Pa ge 25 of 118 2-2 Tools and Equipment Needed You’ll need the following: • Hand tools • Fork lift or overhead lift • Wire, conduit, and fittings for wiring runs (if receptacle is not already in place) • Mounting bolts with nuts and washers • Compressed air tubing and fittings 2-3 Mechanical ...
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Sterling A0567659 - page 26
Page 26 of 118 SGB Batch Blender with Mitsubishi Controller The term IMPORTANT emphasizes areas where equipment damage could result, or provides additiona l information to make a step or procedure easier to understand. Disregarding information marked IMPORTANT would not be likely to cause personal injury. REPORTING A SAFETY DEFECT NOTE: If you beli ...
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Sterling A0567659 - page 27
SGB Batch Blender with Mitsubishi Controller Pa ge 27 of 118 continually reviewed, mainta ined, and improved. Keep minut es or a record of the meetings. Hold daily equipment inspections in additi on to regular maint enance checks. You will keep your equipment safe for producti on and exhibit your commitment to safety. Please read and use this manua ...
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Sterling A0567659 - page 28
Page 28 of 118 SGB Batch Blender with Mitsubishi Controller before starting the unit. • At the beginning of your shift and afte r breaks, verify that the controls and other auxiliary equipment are functioning properly. • Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify, or remove safety guards. Such alteration ...
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Sterling A0567659 - page 29
SGB Batch Blender with Mitsubishi Controller Pa ge 29 of 118 When you need to perform maintenance or repair work on a blender above floor level, use a solid platform or a hydraulic elevator. If t here is a permanently installed catwalk on your blender, use it. The work platform should have secure footing and a place for tools and parts. DO NOT clim ...
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Sterling A0567659 - page 30
Page 30 of 118 SGB Batch Blender with Mitsubishi Controller 2-8-2 Safety Circuit Standards Safety circuits used in industr ial systems protect the operator and maintenance personnel from dangerous energy. They also provide a means of locking out or isolating the energy for servicing equipment. Various agencies have contributed to the establishment ...
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Sterling A0567659 - page 31
SGB Batch Blender with Mitsubishi Controller Pa ge 31 of 118 normal operation of the machine. Some of the safety devices utilize a manual activator. This is the method of initiating the safety lock out. Th is may be in the form of a plug, disconnect plug, lever or a handle. Wi thin this lockable handle, there may be a location for a padlock. Person ...
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Sterling A0567659 - page 32
Page 32 of 118 SGB Batch Blender with Mitsubishi Controller Electrical Disconnect Plug 2-9 Electric Safety Interlock Switch (All Models) A unique electric safety switch is used to shut off power to the blender any time the mixer door is opened. Do not tamper or alter with this switch in any way. Interlock Switch ...
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Sterling A0567659 - page 33
SGB Batch Blender with Mitsubishi Controller Pa ge 33 of 118 Electrical safety interlock s w itch (Located on mixer door) WARNING! Always disconnect and lockout al l electrical power and pneumatic (i.e. compressed air) sources prio r to servicing or cleaning any product, including all SGB Series bl ending systems. Failure to do so may result in ser ...
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Sterling A0567659 - page 34
Page 34 of 118 SGB Batch Blender with Mitsubishi Controller 3-2 In the Event of Shipping Damages Important! According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and p lace of shipment. The Carrier then assumes full responsibility of the shipment. ; Notify the transportation company’s lo ...
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Sterling A0567659 - page 35
SGB Batch Blender with Mitsubishi Controller Pa ge 35 of 118 Parcel Post Shipment ; Notify Sterling at once in writing, giving details of the loss or damage. This information is required for filing a claim with our insurance company. ; Hold the damaged goods with the c ontainer and packing materials for possible inspection by postal authorities. Un ...
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Sterling A0567659 - page 36
Page 36 of 118 SGB Batch Blender with Mitsubishi Controller 3-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact Sterling immediately . For shipments in the United States and Canada, call 1 (800) 233-4819; for all other countries, call our inte rnational desk at 001 (630) 475-7491. Include the order number and item. H ...
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Sterling A0567659 - page 37
SGB Batch Blender with Mitsubishi Controller Pa ge 37 of 118 Installation & Setup 4 4-1 Chapter Description and Objectives It is the intent of this chapter to familiarize the reader with the proper site requirements and installation procedures of the SGB blending system. The information in this chapter is NOT meant to replace or supersede an es ...
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Sterling A0567659 - page 38
Page 38 of 118 SGB Batch Blender with Mitsubishi Controller Verify all clearances on the top and beside the processing machine. This is to insure that all motors, hoppers, control panels, etc. have adequate room for proper operation and servicing. Refer to the assembly drawing wi th the unit for actual height and width dimensions. Note: Allow at le ...
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Sterling A0567659 - page 39
SGB Batch Blender with Mitsubishi Controller Pa ge 39 of 118 4-2-1-2 Mezzanine Mount In a mezzanine mount application, review the following items before installation begins. Fi rst, verify the SGB mounting locations match the mezzanine supports. Verify that the mezzanine is capable of supporting the blender with a full load of material and vacuum l ...
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Sterling A0567659 - page 40
Page 40 of 118 SGB Batch Blender with Mitsubishi Controller 4-2-1-3 Floor Mount (Central Blender) In a floor mounting applicati on, ensure adequate clearance for all blender operations and main tenance. The operator and maintenance personnel must have access to parts of the blender. If necessary, it is the customer’s responsibility to provide ade ...
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Sterling A0567659 - page 41
SGB Batch Blender with Mitsubishi Controller Pa ge 41 of 118 4-3 Installation Overview This section will familiariz e the reader with commonly us ed procedures for blender installation. After reading this chapter , the reader will be familiar with the installation requirements for all SGB blenders. 4-4 Mechanical Installation The installation proce ...
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Sterling A0567659 - page 42
Page 42 of 118 SGB Batch Blender with Mitsubishi Controller assemblies. 4-5 Electrical Installation The standard Sterling SG B blending system is des igned to operate on 120/1/60 supply voltage (220/1/50 CE models are also ava ilable). The current requirements vary with the blender’s size and throughput ra ting. For exact curre nt requirements, c ...
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Sterling A0567659 - page 43
SGB Batch Blender with Mitsubishi Controller Pa ge 43 of 118 4-6 Pneumatic Installation The SGB blending system uses plant-supp lied compressed air to operate the metering and dump valves on the blender. CLEAN AND DRY air must be supplied to the blender. The air supply should be filtered through a 5 micron air filter with a water separator. Oil sho ...
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Sterling A0567659 - page 44
Page 44 of 118 SGB Batch Blender with Mitsubishi Controller SGB blending system. 4-7-2 Weigh Hopper Installation Remove the weigh hopper from the sh ipping box and install it in the blender on the load cell brackets. Connect the airline and close the mixer door, securing the latch. 4-7-3 Load Cell Adjustment The mechanical setup of the SG B blendin ...
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Sterling A0567659 - page 45
SGB Batch Blender with Mitsubishi Controller Pa ge 45 of 118 4-7-4 Final Setup 1. Connect the blender to the appropriate power source . 2. Connect the compressed air piping, ensuring that a 5-micron air filter is installed, along with the proper wate r trap, and lubrication unit, if required. Verify that 60 psi (4.14 bar) of clean, dry compressed a ...
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Sterling A0567659 - page 46
Page 46 of 118 SGB Batch Blender with Mitsubishi Controller 4. The screen shown below allows the operator to control the blender. The blender can be started or stopped and the recipe values can be changed. Other data shown on th is screen consists of the mixer status, recipe status, and feeder type data. The Recipe Screen should startup in the “Q ...
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Sterling A0567659 - page 47
SGB Batch Blender with Mitsubishi Controller Pa ge 47 of 118 Operation 5 5-1 SGB Blender Sequence of Operation 1. Blender is started by turning system on or materi al dropping below level switch in mix chamber. 2. Metering gates are opened to meter mate rial into the weigh hopper in the programmed order. 3. Each component is wei ghed then the batch ...
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Sterling A0567659 - page 48
Page 48 of 118 SGB Batch Blender with Mitsubishi Controller Recipes can also be changed while the blender is running. The new accepted recipe is entered at the beginn ing of the next batch. This allows the operator to modify the new recipe without affecting t he blender until they hit the “Accept New Recipe” button. OR 4. The operator can load ...
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Sterling A0567659 - page 49
SGB Batch Blender with Mitsubishi Controller Pa ge 49 of 118 the blender and the operator is not required to enter it. The ingredient names selected will be disp layed on the run mode display so the operator will know what material is being blended. Important! The #1 hopper (“NAT” - Virgin Materi al) recipe ingredient will not be shown on the r ...
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Sterling A0567659 - page 50
Page 50 of 118 SGB Batch Blender with Mitsubishi Controller The preset part will be divided by t he total of all parts, with each part representing the ca lculated weight for ratio control. Example of a 5-component Blend in “Parts” Mode Feeder Tag Preset Part Calculated Weight (Ratio Control) Virgin #1 7,200 7,200/10,000 Regrind #2 2,000 2,000/ ...
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Sterling A0567659 - page 51
SGB Batch Blender with Mitsubishi Controller Pa ge 51 of 118 5-4 SGB Series Control System Menu Structure “Recipe Book” Page ¾ Save the running r ecipe to the book ¾ Delete a st ored recipe ¾ Load a sto red recipe ¾ Erase all stor ed recipes ¾ Modify the pr oduct ID for a stored re cipe ¾ Return to the “Recipe” page “Clean Out” Pa ...
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Sterling A0567659 - page 52
Page 52 of 118 SGB Batch Blender with Mitsubishi Controller 5-5 Blender Calibration *NOTE: It is not necessary to calib rate the weight scale on a brand new blender, although it is recommended that the calibration be checked periodically to ensure that the reported inventory totals are accurate. Remember that in most cases a bad calibration is wors ...
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Sterling A0567659 - page 53
SGB Batch Blender with Mitsubishi Controller Pa ge 53 of 118 time the mixer will mix or the batch is dumped. 3. Enter a “Mixing Time” by pressing the number next to “sec”, this is the amount of time to run the mixer after a batch is dumped into the mixing chamber. Remember that if the mix time is too long you may get material separation. 4. ...
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Sterling A0567659 - page 54
Page 54 of 118 SGB Batch Blender with Mitsubishi Controller 5-5-4 Verifying Calibration (Reco mmended on a periodic basis to ensure accuracy) 1. Login by touching “login” from the Inventory Page and enter “5413”, then touch the Sterling logo to access setup. 2. Touch “Calibration” and then “Direct Scale Readout”. 3. Remove the weigh ...
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Sterling A0567659 - page 55
SGB Batch Blender with Mitsubishi Controller Pa ge 55 of 118 Inventory Shutdown: This feature a llows the blender to make a certain amount of material at a time. If this feature is set to “0” then the feature will be di sabled. If this option is used, the blender will ma ke the set amount of material and will then shut down and wait for the ope ...
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Sterling A0567659 - page 56
Page 56 of 118 SGB Batch Blender with Mitsubishi Controller **Note: The blender monitors the ope rator’s entries and determines if the recipe is valid before accepting the ne w recipe. If there is an error (such as the recipe does not add up to 100% and the blender is in Percentage Mode.) then a message is shown on the Recipe screen to alert the ...
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Sterling A0567659 - page 57
SGB Batch Blender with Mitsubishi Controller Pa ge 57 of 118 the blender where there are moving parts. 4. Remove the weigh hopper by unplug ging the air line disconnect fitting, holding the dump valve closed, lifting the hopper to clear the load cell brackets, and gently pulling the we igh hopper out of the blender. Important! To reduce the chance ...
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Sterling A0567659 - page 58
Page 58 of 118 SGB Batch Blender with Mitsubishi Controller 5-8 Additional Operation Features 5-8-1 Display Description (LCD) The SGB blending system utilizes a standardized menu format. Each screen was designed to be user-friendly and provide the operator with the necessary information to run the blender. A typical menu is shown in the figure abov ...
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Sterling A0567659 - page 59
SGB Batch Blender with Mitsubishi Controller Pa ge 59 of 118 5-8-2 Weigh Hopper (Load Cell) Calib ration on blenders equipped with an OptiMix mixer Enter the Setup menu as described previously. See Section 5-3 for menu tree. The factory pre-calibrates the weigh hopper on the SGB blenders. Button #3 on the Setup Menu is “Calibra tion”. Press it ...
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Sterling A0567659 - page 60
Page 60 of 118 SGB Batch Blender with Mitsubishi Controller 5-8-3 Mix Timer The mix timer is the amount of ti me that the mix motor will mix the material after it has entered the mi xing section of t he SGB blender. The timer has a range of 1 to 999 seconds. To set the value of the mix timer, t he user must gain access to the Setup Menu. After ente ...
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Sterling A0567659 - page 61
SGB Batch Blender with Mitsubishi Controller Pa ge 61 of 118 mix cycle after each dump of the weigh hopper. To view and change the value of the re-m ix timer, refer to the “Mixer and Dump Setup” menu. A ll current values for Mixing and Remixing Times will be shown on this screen. The re-mix timer default value is factory preset at zero. 5-8-5 M ...
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Sterling A0567659 - page 62
Page 62 of 118 SGB Batch Blender with Mitsubishi Controller and Dump Setup” screen, and then select “Dump Delay”. The default time is factory set at zero seconds. This delay time is used to start the mixer prior to dumping the material from the weigh hopper into the mix chamber of the blender. 5-8-8 Weigh Hopper Dump Cycle The dump cycle allo ...
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Sterling A0567659 - page 63
SGB Batch Blender with Mitsubishi Controller Pa ge 63 of 118 3.) Select a feeder (1-6) by t ouching the “Select Feeder” box. 4.) The current settings for the hopper that you have chosen will now be shown on the screen. 5.) Make the necessary adjustments to the “Stop/Continue if “Out of Material,” Alarm/No Alarm on “Out of Material,” a ...
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Sterling A0567659 - page 64
Page 64 of 118 SGB Batch Blender with Mitsubishi Controller • Calibration Error, Clean out hopper and check calibration: This alarm indicates that the maximu m empty weight for the weigh hopper has been exceeded. The blender will automatically tare up to 0.25 lbs of material, but if this weight is exce eded, then an alarm will appear. This alarm ...
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Sterling A0567659 - page 65
SGB Batch Blender with Mitsubishi Controller Pa ge 65 of 118 • E-Stop Screen: The blender is equipped with an E-stop switch that removes the power from all mechani cal outputs. Th e E-Stop Screen appears along with an audible al arm whenever the E-Stop is activated. The operator can not access any screens until E-Stop is deactivated. The Panel Vi ...
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Sterling A0567659 - page 66
Page 66 of 118 SGB Batch Blender with Mitsubishi Controller This screen will allow you to Open or Close the Feeder, Weigh Hopper, Mixer Knife Gate, Empty the Entire Blender, Start or Stop the Mixer Motor, Test the Alarm Output, Find out the Mixer Proximity Status and monitor the Current Hopper Weight. The dump valve opens as soon as the “Press to ...
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Sterling A0567659 - page 67
SGB Batch Blender with Mitsubishi Controller Pa ge 67 of 118 the mixer section of the blender. If t he dump delay is set, the mixer will start before the weigh hopper dump will open for the selected time. The blender will sit at rest until t he high-level sensor in the mixing chamber is uncovered to start anot her weigh cycle. (Unless the Re-Mix ti ...
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Sterling A0567659 - page 68
Page 68 of 118 SGB Batch Blender with Mitsubishi Controller This display indicates the amount of material in pounds that has been used by each feeder of the recipe. It is important to note that the weights are rounded off to the closest pound. On minor ingredients, several cycles may have to occur to show an inventory number. In addition to showing ...
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Sterling A0567659 - page 69
SGB Batch Blender with Mitsubishi Controller Pa ge 69 of 118 • Recipe Book Page • Recipe Format Upon Start Up, the blender controller will default to the “Recipe Menu” screen. The “Recipe Book” screen can be accessed in the “Recipe Page” and is useful in storing and retrieving recipes. The Recipe format option can be accessed in the ...
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Sterling A0567659 - page 70
Page 70 of 118 SGB Batch Blender with Mitsubishi Controller can be scrolled to read “NAT” (natur al), “RGD” (regrind), or “ADD” (additive). The selected label will be displayed for the ingredient hopper with an arrow next to the abbreviation. Component #3 is designed to ha ndle regrind and most models come equipped with a larger, squa r ...
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Sterling A0567659 - page 71
SGB Batch Blender with Mitsubishi Controller Pa ge 71 of 118 Example calculations of a five (5) -component blend in “Quick Set” Virgin (NAT): ??? Additive1 (ADD): 5.00% - of virgin component Regrind (RGD): 30.00% - of total batch Additive2 (ADD): 2.00% - of virgin component Additive3 (ADD): 1.00% - of virgin component Batch Size: 10.00 lbs. Tot ...
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Sterling A0567659 - page 72
Page 72 of 118 SGB Batch Blender with Mitsubishi Controller Typical Batch Size SGB-450 3 lbs. SGB-900 8 lbs. SGB-2500/4000/5000 35 lbs. 5-8-17 Batch Size Menu The SGB blending system is a gr avimetric batching system. The blender will weigh a prepr ogrammed batch of material each cycle. This batch size is determined by the blender ’s weigh hopper ...
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Sterling A0567659 - page 73
SGB Batch Blender with Mitsubishi Controller Pa ge 73 of 118 When the Inventory Shutdown value is reached, the blender will finish the current batch of material. It wi ll then stop and display to the operator that the inventory value has been r eached. Additionally, it will flash an alarm and wait for operator attention. An example of this screen i ...
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Sterling A0567659 - page 74
Page 74 of 118 SGB Batch Blender with Mitsubishi Controller Always verify that the Current Reci pe is showing what y ou want to run, and that the correct recipe has been downloaded from the book. The recipe book section contains the following Items: • Save Running Recipe to the Book • Load a Stored Recipe from the Book • Display a Stored Reci ...
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Sterling A0567659 - page 75
SGB Batch Blender with Mitsubishi Controller Pa ge 75 of 118 5-8-19-2 Load a Saved Recipe from the Book The load from book function allows the operator to retrieve a previously stored recipe from t he recipe book and install it into the current recipe menu. This will overwrite the current recipe, so make sure that it has been saved to the book befo ...
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Sterling A0567659 - page 76
Page 76 of 118 SGB Batch Blender with Mitsubishi Controller 5-8-20 Controller Features 5-8-20-1 Display Time and Date The display Time and Date item in the upper right corner of the “F940 Config” menu is used to verify the current time and date information. 5-8-20-2 Setting Date & Time The Set Date & Time feature is located in the “Pa ...
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Sterling A0567659 - page 77
SGB Batch Blender with Mitsubishi Controller Pa ge 77 of 118 5-9 Stroke Limiters for Metering Gates Stroke limiters are supplied on components 1 through 4 with all SGB blenders to allow standard metering gates to meter small amounts of low percentage additive materials. Generally, the stroke limiter (Item 30) is not required on major ingredients (u ...
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Sterling A0567659 - page 78
Page 78 of 118 SGB Batch Blender with Mitsubishi Controller M a i n t e n a n c e 6 6-1 Work Rules The installation, operation, and maintenanc e of this equipment must follow all applicable work and safety codes for the location where it is used. This may include, but is not limited to, OSHA, C SA, NEC, SPI, and other local, national, and internati ...
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Sterling A0567659 - page 79
SGB Batch Blender with Mitsubishi Controller Pa ge 79 of 118 6-3 Controller Setup This section describes t he proper setup of the SG B blending system control parameters. These paramet ers are operator changeable; however, these items should only require setup during the init ial installation. On ly authorized personnel should change them. For secu ...
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Sterling A0567659 - page 80
Page 80 of 118 SGB Batch Blender with Mitsubishi Controller 6-4 SGB Series Blender Menu Structure “Recipe Book” Page Save the running r ecipe to the book ¾ Delete a st ored recipe ¾ Load a sto red recipe ¾ Erase all stor ed recipes ¾ Modify the pr oduct ID for a stored re cipe ¾ Return to the “Recipe” page “Clean Out” Page ¾ Empty ...
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Sterling A0567659 - page 81
SGB Batch Blender with Mitsubishi Controller Pa ge 81 of 118 6-5 Mechanical The mechanical design of the blender is very simple and very little maintenance is required. The only moving parts are the metering gates, weigh hopper dump valve and mixer agitator. The fo llowing maintenance is suggested: Daily • Inspect blender for any loose par ts-tig ...
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Sterling A0567659 - page 82
Page 82 of 118 SGB Batch Blender with Mitsubishi Controller 6-6 Electrical 6-6-1 Description and Objectives This section is designed to give the operator an overview of the electrical system that controls the SGB blen ding system. Since the SGB’s control panel is a self-contained pluggable item, seldom will a maintenan ce person be required to en ...
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Sterling A0567659 - page 83
SGB Batch Blender with Mitsubishi Controller Pa ge 83 of 118 6-6-4 Output Signals from Programmable Controller The SGB blending system uses several output control signals to control the process. All of these are very simila r in nature, the first of which is the mixer motor control. The mixer motor is controlled by a PLC output. The weigh hopper du ...
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Sterling A0567659 - page 84
Page 84 of 118 SGB Batch Blender with Mitsubishi Controller 6-7 Pneumatic System Maintenance The SGB blending system uses plant-supp lied compressed air to operate the metering and dump valves on the blender. It is the user’s responsibility to provi de CLEAN AND DRY air for the blender to be connected to. The air supply should be filtered through ...
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Sterling A0567659 - page 85
SGB Batch Blender with Mitsubishi Controller Pa ge 85 of 118 7 Troubleshooting 7-1 Description and Objectives This section provides basic troubleshoot ing procedures to common SGB blending system problems. Any problem encountered that is not listed should be discussed with an Sterling service technician. Problem Possible solution Check to make sure ...
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Sterling A0567659 - page 86
Page 86 of 118 SGB Batch Blender with Mitsubishi Controller Problem Possible solution Check batch weight setting in the recipe menu. See th e setup chapter for more information. Check the load cells and weigh hopper mounting for binding, etc. Check to see that a pellet has not lodged under a load cell. Check the ingredient suppl y hoppers to verify ...
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Sterling A0567659 - page 87
SGB Batch Blender with Mitsubishi Controller Pa ge 87 of 118 Problem Possible solution Check the Mixer and Dump Setup to see if the mixer is co nfigured for “Continuous Mixing”. Set it to “Timed Mixing”. Check the value of the mixer timer setting. Check the value of the dump delay timer. Check the mixer motor fuse. This is located in the co ...
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Sterling A0567659 - page 88
Page 88 of 118 SGB Batch Blender with Mitsubishi Controller Weigh hopper does not empty completely. Check the dump time setting. It may be set too s hort. If this does not correct the problem, clea n the weigh hopper and reche ck the scale diagnostics readout. If not showing (0) zero when empty, re- calibrate the scale. Problem Possible solution Bl ...
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Sterling A0567659 - page 89
SGB Batch Blender with Mitsubishi Controller Pa ge 89 of 118 8 Blender Options The following is a list of options, which your blender may hav e been equipped with: Regrind Auger Metering (RAM) Used for feeding difficult regrind materials . Low Level Sensors Detects material supply problems before blender runs out. Remote Touch Screen Interface Allo ...
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Sterling A0567659 - page 90
Page 90 of 118 SGB Batch Blender with Mitsubishi Controller Spare Parts 9 9-1 Spare Parts List SGB Series Gravimetric Batch Blending Systems 9 Please see Section 9-2 for parts iden tification and exploded views. Model SGB-450 Part No. Description 53292 Air Cylinder (weigh hopper dump) 53272 2kg Load Cell 10220 Mixer Agitator (Opti-Mixer) A0556548 M ...
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Sterling A0567659 - page 91
SGB Batch Blender with Mitsubishi Controller Pa ge 91 of 118 A0565882 Calex Module A0569702 PLC A0569708 SGB Graphics Panel A0542200 1.5 Amp Fuse A0542207 3.0 Amp Fuse A0569108 Calibration Weight (~25 lbs.) 9-2 Model SGB Blender System Component Description This section describes the various co mponents of the blending system. The SGB blending syst ...
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Sterling A0567659 - page 92
Page 92 of 118 SGB Batch Blender with Mitsubishi Controller 9-2-2 Typical Mixer Section (Front) Typical Opti-Mixer™ - Front Assembly Detail ...
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Sterling A0567659 - page 93
SGB Batch Blender with Mitsubishi Controller Pa ge 93 of 118 01 Nameplate an d indicator mounting pl ate 02 Nameplate 03 Upper poly carbonate Opti-M ixer™ door 04 Door clamp 05 “Caution” label 06 Lower stainless steel Opti -Mixer™ door 07 Mixer agitator door bushing 08 Door hinge 09 Door hinge base 9-2-3 Typical Mixer Section (Rear) Typical ...
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Sterling A0567659 - page 94
Page 94 of 118 SGB Batch Blender with Mitsubishi Controller 10 Opti-Mixer™ back plate 11 Cover plate 12 Back control panel 13 Cover plate 14 Proximity sensor ( Mixer “high” level) 15 Mixer proximity sensor mounting plate 16 Mixer gear motor 17 Mixer agitator shaft coupling 9-2-4 Typical Mixer Frame ...
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Sterling A0567659 - page 95
SGB Batch Blender with Mitsubishi Controller Pa ge 95 of 118 Typical Opti-Mixer™ Frame Assembly 18 Hinge mounting bracket 19 Mixer door clamp 20 Load cell cover 21 Opti-Mixer™ top plate 22 Opti-Mixer™ frame 23 Warning label 24 Opti-Mixer™ frame side panel 25 Hinge mounting bracket ...
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Sterling A0567659 - page 96
Page 96 of 118 SGB Batch Blender with Mitsubishi Controller 9-2-5 Typical Gate Assembly Typical SGB Series Diamond Gate Assembly Detail 28 Slide gate guide rod 29 Stainless steel gate assembly base 30 Slide gate stop (stroke-limiter) 31 Retaining clip 32 Slide gate air cylinder 33 Slide gate air cylinde r pneumatic conne ctor fitting 34 Slide gate ...
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Sterling A0567659 - page 97
SGB Batch Blender with Mitsubishi Controller Pa ge 97 of 118 Typical SGB-450 Series Hopper Assembly Detail 40 Mild steel hopper cover 41 Hopper inse rt (square to dia mond-polyurethan e) 42 Mild steel hopper 43 Gasketing 44 Polycarbonate access door 45 N/A 46 Polycarbonate hop per sight glass 47 Blow-off tool holder 48 Blow-off tool 49 Drain plug 5 ...
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Sterling A0567659 - page 98
Page 98 of 118 SGB Batch Blender with Mitsubishi Controller Typical Weigh Hopper & Load Cell Detail 52 Left weigh hopper br acket 53 Inside mixer pl ate 54 Weigh Hopper 55 Weigh hopper discha rge air cylinde r pneumatic conne ctor 56 Weigh hopper discha rge air cylinde r 57 Weigh hopper discha rge air cylinder m o unting bra cket 58 Weigh hoppe ...
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Sterling A0567659 - page 99
Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 783- 7835 or call [262] 641- 8600, Fax [262] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality p arts manufactured to engi neering design specifications, which will maximize your e quipment’s performance and efficiency. T o assist i ...
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Sterling A0567659 - page 100
Page 100 of 118 SGB Batch Blender with Mitsubishi Controller 10-2 Returned Material Policy 10-2-1 Credit Returns 1. Prior to the return of any material authorization must be given by Sterling. A RMA number will be assigned for the equipment to be returned. 2. Reason for requesting the return must be given. 3. ALL returned material purchased from St ...
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Sterling A0567659 - page 101
SGB Batch Blender with Mitsubishi Controller Pa ge 101 of 118 10-3 Warranty Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of e ...
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Sterling A0567659 - page 102
Page 102 of 118 SGB Batch Blender with Mitsubishi Controller Safety Tag Information 11 11-1 SGB Blender Safety Tags Pinch Point Read Operation Slide Gate and Installation Manual Shear Point Earth Ground Rotating Mixer High Voltage PE Protected Earth Inside Enclosure Ground Shear Hazard Rotating Auger Lifting Point ...
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Sterling A0567659 - page 103
SGB Batch Blender with Mitsubishi Controller Pa ge 103 of 118 11-2 Pushbutton and Touchscreen Tags Button F u n c t i o n Turns power on to the blender controller. (Found on back of controller.) Power On Turns power off to t he blender controller. (Found on back of controller.) Power Off Stops blender & re-starts controller. Press to move back ...
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Sterling A0567659 - page 104
Page 104 of 118 SGB Batch Blender with Mitsubishi Controller 11-3 Blender Identification (Serial Number) Tag (Located on back of mixing chamber) SGB Series Blender Model Number SGB-900 Max Blend Capacity 318 KG/HR 220V Serial Number 060701R 1 Ǿ Date of Manufactu re 06/2002 4.5A Over-current Protection Device (s) 4.5A Total Frequency 50/60Hz Compre ...
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Sterling A0567659 - page 105
SGB Batch Blender with Mitsubishi Controller Pa ge 105 of 118 12 Appendix Important! Hidden, programmable features and hidden menu pages should not be made available to floor operators. These pages include the Service Supervisor Information a ddendum located in this section. Unauthorized changes to these factory settings by inexperienced operators ...
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Sterling A0567659 - page 106
Page 106 of 118 SGB Batch Blender with Mitsubishi Controller 12-1-2 Factory Setup Menu Available Selections Metering Test Screen This screen is useful in both R & D and development purposes when testing the metering performance of each feeder. The user can perform a “Single Meter by Weight” to evaluate the mechanical standard deviation of t ...
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Sterling A0567659 - page 107
SGB Batch Blender with Mitsubishi Controller Pa ge 107 of 118 introduced material into the weigh hopper, adjust the Maximum Em pty Weight of the hopper. The weight filter is the specialized filter algorithm that smoothes erroneous load cell readings. The signal will be filtered more if this value is increased and less if decreased. This setting sho ...
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Sterling A0567659 - page 108
Page 108 of 118 SGB Batch Blender with Mitsubishi Controller Feed Calibration Options Screen This screen allows you to perform the feeder calibrations for each feeder (in weight per second). This is useful when the feed calibration is giving you an error message (most commonly caused by overfilling the hopper during the calibration). Select a feede ...
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Sterling A0567659 - page 109
SGB Batch Blender with Mitsubishi Controller Pa ge 109 of 118 Feeder Setup This screen allows you to modify the type of each feeder. In most cases, t he user will want to keep regrind on hopper 3 because that blender has been specifically designed to handle the regrind. These settings should only be modified under special circumstances. If the blen ...
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Sterling A0567659 - page 110
Page 110 of 118 SGB Batch Blender with Mitsubishi Controller box. 2. The current settings fo r that hopper will be shown. 3. Make the necessary adju stments and select a new feeder to configure if desired. 4. Hit “Done” to exit. Alarm This screen shows the last 100 stored alarms. The log Log can be viewed and cleared. Programmable Features (con ...
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Sterling A0567659 - page 111
SGB Batch Blender with Mitsubishi Controller Pa ge 111 of 118 Information included in this manual is subject to change without notice. Remember: Blender controller default password is “5413” Service Notes ...
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Sterling A0567659 - page 112
Page 112 of 118 SGB Batch Blender with Mitsubishi Controller 12-2 Passwords User Password “5413” Maintenance Password “3145348” CAUTION! Maintenance password should only be supplied to qualified personnel! T he program can be compromised. 12-3 Default Values (factory defaults shown): SGB BLENDER CONFIGURATION PARAMETERS Model Number/Type SG ...
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Sterling A0567659 - page 113
SGB Batch Blender with Mitsubishi Controller Pa ge 113 of 118 Dump Delay 0 Dump Cycles 2 1 Mixer Dump Time 4 6 5 Continuous/Timed Mixing TIMED USER PASSWORD User Password 5413 Maintenance Password 3145348 SGB BLENDER CONFIGURATIO N PARAMETERS Cont’d. Model Number/Type SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 ALARM SETUP Hop1 Continue/Stop on Ou ...
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Sterling A0567659 - page 114
Page 114 of 118 SGB Batch Blender with Mitsubishi Controller Hop6 Allowed Underfeed Double Gate Threshold 5 Out of Material Retry limit before alarm Batches for process rate 10 Process Rate Filter 3 SGB BLENDER CONFIGURAT ION PARAMETERS Cont’d. Model Number/Type SGB-450 SGB-900 SGB-2500 SGB-4000 SGB-5000 FEED CAL OPTIONS Hop1 Batch % for feeder c ...
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Sterling A0567659 - page 115
SGB Batch Blender with Mitsubishi Controller Pa ge 115 of 118 Service Notes ...
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Sterling A0567659 - page 116
Page 116 of 118 SGB Batch Blender with Mitsubishi Controller Service Notes ...
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Sterling A0567659 - page 117
SGB Batch Blender with Mitsubishi Controller Pa ge 117 of 118 Service Notes ...
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Sterling A0567659 - page 118
Page 118 of 118 SGB Batch Blender with Mitsubishi Controller ...
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