Declining Weight Blending System Quick Start Manual 12285 E Main St Marshall, IL 62441 Phone: 217-826-6352 Fax: 217-826-8551 Website: www.yargus.com
P a g e 2 MAIN SCREEN The MAIN SCREEN on the cover page is what you will see whenever the system starts up or if a power cycle were to occur. Your User Password is set to: 1111. After entering the User Password, you can navigate to any location in the system by using the buttons that appear at the bottom of the screen. Most of your interactions will occur on the Valve Menu and the Aux Menu which will be explained in further detail throughout the course of this manual. (Note: Yargus Password is only for Yargus Technicians.)
P a g e 3 Valve Settings Screen The following adjustments to your individual valves can be made from this screen: Valve Name (*) used for entering product names or descriptions. Valve Delay (**) used to enter timing delays for blending. Bulk Density/Specific Gravity (*) used to enter the Bulk Density or Specific Gravity of a product being used in blending. Volume Constant (**) used to enter the volume per revolution of each individual valve.
P a g e 4 Single/Double Valve used to set up the hopper with the correct amount of valves for calculating material flow. System Feedback used to ignore system alarms in extreme circumstances or when instructed by a Yargus Technician. (*) It is recommended that you change the Valve Name and Bulk Density/Specific Gravity when changing the product being dispensed from your system to keep an accurate blend. (**) It is not recommended that you change this value after your Yargus Technician has calibrated each valve. Please contact Yargus at 217-826- 6352 for troubleshooting.
P a g e 5 Blend Entry Screen You can enter the specific details of your blend from this screen: Valve 1-8, 9-16, 17-24, etc. show the name of the product being dispensed and any Alarms will flash here if they have been triggered. Blend Entry allows you to enter the amount of product being dispensed into the blend in weight for dry products or volume for liquid products. Valve RPM shows you the calculated RPM for that valve after amounts have been entered; and Single/Double allows you to select how many valves will operate on that particular hopper should you wish to choose a slower or faster dispensing time.
P a g e 6 Current Scale Weight shows you the current weight of product within the hopper; weights do not display for liquid product as they are dispensed by volume and not weight. Prev/Next buttons will take you from screen to screen of valves should you have more than eight valves in your system. Reset Alarm button will flash to let you know if an Alarm has occurred within your system. Types of Alarms include: o Bridge (A or B) Alarm: this indicates that the product within the hopper is not in proximity to the sensor or has bridged up and is not flowing out of the valve. First, take steps to eliminate bridging by engaging the vibrators or manually eliminating the bridge; then reset the Alarm. o Motion (A or B) Alarm: this indicates that the valve, or flow meter on an impregnation unit, is not in motion. First, take steps to verify that there is power to all units; then reset the Alarm. DO NOT WORK ON LIVE WIRING! TURN OFF THE POWER FIRST IF YOU NEED TO VERIFY PHYSICAL CONNECTIONS TO THE DRIVE UNITS!! o Too Rich Alarm: this indicates that one or more of the valves have been calculated to run too slowly for your system to work correctly. First, take steps to verify that you have entered the blend correctly; when you re-enter the correct blend amounts the Alarm will go away. Clear Blend button will reset all entered weights and volumes to zero that you had previously entered for your last blend. o If you do not Clear Blend, then the values will be retained in those fields so that you can run another blend with the same values. o If you want to run a blend with different values, then press Clear Blend before entering new weights and volumes for your new blend. Run Blend button will flash and take you to the Initiate Blend Screen once you have entered blend amounts and the calculations have been verified to meet the conditions to run a blend
P a g e 7 Initiate Blend Screen You cannot enter this screen without having entered a verified blend and making sure all Alarms are reset; or without having entered a verified blend and ignoring System Feedback. The following buttons appear on this screen in different stages of the blending: Start button will begin the blending process by activating any load-out conveyances and under-bin conveyances, then it will continue the blending process by initiating the valve sequence for the blend. Timer is used to display how much time is left for the blend.
P a g e 8 Valve 1-8, 9-16, 17-24, etc. show the current weight in each hopper, the product name on each valve, the amount entered for the blend on each valve, the current RPM on each valve, and the Rate of Change (ROC) on each valve. Total Dry Weight, Total Liquid Weight, and Total Blend Weight display across the bottom of the valves to give you a total blend weight. System Feedback will flash to Feedback Ignored if you are ignoring system feedback to initiate a blend. Monitor button will appear once you have started a blend so that you can monitor the ROC, Rate of Change, of dry and liquid valves during a blend. Pause button will appear in the place of the Start button should you need to disrupt the blend process. If you press the Pause button, then a Cancel button and Start button will appear. o Start button will resume your blend from the point that it was paused, even given any unique constraints of your system. o Cancel button will ask again if you really want to Cancel the blend, and if you do then your blend will not be able to resume from this point again. You will have to start a new blend at this time, and the screen will return to the Blend Entry screen.
P a g e 9 Alarm Definitions Alarms could be triggered within the system and cause a Pause situation to occur or stop the system from running a blend. The first thing to remember is: Don t panic! The second thing to remember is that you can usually remedy the cause of the Alarm situation by logically troubleshooting the system. Read on below to learn about Alarms and their causes: Bagger Full Alarm on systems equipped with overhead tanks that feed a bagging system will alert you that the hopper feeding the bagging system has triggered the sensor at the top of the hopper causing the system to Pause. To remedy the situation, simply bag off any product in the hopper, Reset Alarm, and Start your blend again. Occasionally, the sensor itself might need cleaned off to maintain operation. Please consult the sensors operation manual for more details. Bin Full Alarm on systems equipped with an overhead tank system can trigger when the bin becomes full and product backs up the leg which then triggers the Bin Full Switch which causes the whole system to Pause. This can be detrimental to your systems well-being as the bucket elevator leg and any load out conveyance will then be paused under a full load. Blend Too Rich Alarm can occur when the ratio of products you are blending are unable to be achieved within your system s parameters. For example, when you have a system with several high capacity valves and try to run a relatively small amount of one product versus a relatively large amount of another product, then the system will calculate an RPM for the least amount valve that is too low for it to turn. This would make the blend too rich of the larger product amount and trigger this Alarm. Recalculate or readjust your ratio of products so this situation does not occur. Bridge Alarm can occur due to the following circumstances: o On your first blend of the day, or several days, where the product has packed in and isn t flowing well yet which could cause it to
P a g e 10 build up over the metering valve or bridge. When this occurs the Bridge Alarm will signal and Pause the blend. o When the hopper is empty of product the Bridge Alarm will signal and Pause the blend. o Less frequently the Bridge Sensor itself might need adjustment or replacement: if you feel this is the case, then please call and talk to a Yargus Manufacturing Service Technician at 217-826-6352. Conveyance Alarm can occur when the sensor for any piece of conveyance is not detecting that the piece of conveyance is running. Check for the following situations: o If you can visually see and hear the conveyance running when you run it manually or within the touch screen, then you might have a sensor issue. Please check the following situations to help eliminate issues: Check to make sure the sensor has not wiggled out of its sensing position. When it wiggles back even a little far from the magnetic disc it might cause a misread and trigger the alarm. Check to make sure the sensor has all of the wires plugged in. Occasionally the plug itself inside the sensor can unplug itself and needs to be reseated. Less frequently a sensor might go bad and need replaced: if you feel this is the case, then please call and talk to a Yargus Manufacturing Service Technician at 217-826-6352. o If the conveyance is not running, and you cannot get the conveyance to run by hand switch; then, you might have the following situations: Your motor starter overload protection has tripped; check your LEC panel and reset the overload protection. If the condition repeats and persists, then please call and talk to a Yargus Manufacturing at 217-826-6352. Your motor fuses may have blown; check your LEC panel and use a continuity test to ensure the integrity of the fuses.
P a g e 11 If they re bad, then replace the fuses and monitor the situations to make sure that the conveyances aren t continually blowing a fuse. If the fuses continue to blow, then make sure that you don t have any obstruction that is binding the conveyance. This is particularly true in the case of under-bin, incline, mix, or cross-blend augers due to the possibility of the fluting being jammed from a foreign object or build up. D/W Flow Rate Alarm can be triggered by a few situations: o When the blend is running and the Rate of Change (ROC) is not high enough, then the valve will try to run faster up to 90rpm. If it still cannot reach the desired ROC, then after a set number of occurrences the system will Pause. o When the blend is running and the ROC is gaining weight, but the system has not detected a Fill situation then the system will Pause. o When the blend is running and the valve is calculated to run below 1rpm, then the system will Pause. E-Stop Alarm is triggered by any safety E-Stop button or safety pull cable. o An E-Stop Alarm will stop all moving parts of the system immediately. o After an E-Stop situation, the system will not resume its running state until the button or cable pull has been reset. o Please make sure the system is clear and safe to operate before resetting the E-Stop. After doing so, then you may resume the blend. Flow Alarm will trigger on an impregnation unit if you have a less than a 0.05 rate on your flow meter which could occur from a few circumstances: o Check your tank to ensure that liquid product is full and the tank isn t empty. o Check all valves to make sure that liquid can make it to the pump.
P a g e 12 o Check for any obstructions in the hosing, in particular if you ve been through a freezing period, then some liquid product can set up in the hoses and cause an issue. o Less frequently you might need to replace a flow meter: if you feel this to be the case, then please contact a Yargus Manufacturing service technician at 217-826-6352. Motion Alarm can occur due to the following circumstances: o Power loss to the VFD that controls the valve will result in a Motion A (or B) Alarm. Check to make sure the overload in the VFD isn t tripped. Check to make sure the switch on the VFD box is in the On position. Check to make sure any disconnects are in the On position. Check the LEC three-phase panel to make sure it s on and that the fuses for the VFDs have continuity. o An error condition within the VFD itself will result in a Motion A (or B) Alarm; turn off the drive, pause for 5 seconds, and turn on the drive. If the condition persists, then not the error code and please call and talk to a Yargus Manufacturing Service Technician at 217-826-6352.
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