Operating Instructions: Lift & Blend Column

OPERATING
INSTRUCTIONS
Lift & Blend Column
FTMH 1000 MG5
Böhringer Disol Columbia
O. Nr.: 18899
Kom. Nr.: 020015
Table of contents
1 Preface...................................................................................................................................3
2 General Notes .......................................................................................................................3
3 Projectinfo .............................................................................................................................4
3.1 Project Details .................................................................................................................4
3.2 General............................................................................................................................4
4 Control panel (+CP) ..............................................................................................................5
5 Operator Panel 1 (+OP1 on Control Panel) ........................................................................6
5.1 Elements on Operator Panel 1 ........................................................................................6
5.2 Functions of Operator Panel 1 ........................................................................................7
5.2.1 Ground position Lifting Column................................................................................7
5.2.2 Load Operation ........................................................................................................7
5.2.3 Unload Operation .....................................................................................................8
5.2.4 Picture 1: Blending not possible...............................................................................8
5.3 Blending Operation..........................................................................................................9
5.3.1 Picture 2: Blending permitted...................................................................................9
5.3.2 Picture 3: Select Program Number ..........................................................................9
5.3.3 Picture 4: Blend Speed / Time .................................................................................9
5.3.4 Picture 5: Time actual / Time remaining ................................................................10
5.3.5 Picture 6: Turning to zero position .........................................................................10
5.3.6 Picture 7: Blending completed ...............................................................................10
5.4 Special Cases ...............................................................................................................11
5.4.1 Picture 8: Blending stopped ...................................................................................11
5.4.2 Picture 6: Turning to zero position .........................................................................11
5.4.3 Picture 9: Blending aborted....................................................................................11
5.4.4 Picture 10: Set Blending Program Parameters......................................................12
6 Operator Panel 2 (+OP2) ....................................................................................................13
6.1 Elements on Operator Panel 2 ......................................................................................13
6.2 Functions of Operator Panel 2 ......................................................................................13
7 Errors ...................................................................................................................................14
7.1 General Faults ...............................................................................................................14
7.1.1 Error 1: Emergency Stop .......................................................................................14
7.1.2 Error 2: Air Pressure not OK ..................................................................................14
7.1.3 Error 3: Door not closed .........................................................................................15
7.2 Lifting Faults ..................................................................................................................16
7.2.1 Error 4: Overload....................................................................................................16
7.2.2 Error 5: Motor/Break not OK ..................................................................................16
7.3 Blending Faults..............................................................................................................17
7.3.1 Error 6: Motor/FC/Thermistor not OK.....................................................................17
AUTOMATION
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Version issued Vis checked Vis Operating Instructions

0.0 21.10.02 JS Böhringer Disol Columbia
© SAIAG 2001 Page 2 / 17
02-088 Operating Instructions.doc
1 Preface
This document is written to help the user to operate the control system correctly.
Rev. Date: Author: Description:
0.0 21. October 2002 Josua Schaub First issue
1.0
2.0
3.0
4.0
2 General Notes
Always follow the warning and safety notes contained in this user manual. Safety notes are:
Electrical hazard, e.g. when working on live equipment.
Mechanical hazard, e.g. when working on hoists.
Important instructions for safe and fault-free operation.
A requirement for fault-free operation and fulfilment of any rights to claim under guarantee is
that these instructions and remarks are followed. Therefore read these instructions carefully
before you start working with the unit! AUTOMATION
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© SAIAG 2001 Page 3 / 17
3 Projectinfo
3.1 Project Details
Client: Böhringer Disol Columbia
Object: Lift & Blend Column

FTMH 1000 MG5
Serial No. 025005 / O-Nr. 18899
3.2 General
On the following pages you’ll find the description of the control system for the Lift & Blend
Column FTMH 1000 MG5.
The main component of the control system is the control panel (+CP).
It contains all push buttons and one Emergency Stop push button. Every possible function can
be activated from this operator panel (+OP1) as well as for showing error messages.
To operate the system into the filling room there is one operator panel (+OP2) provided.
- It contains one Emergency Stop push button and push buttons to raise and lower the
Lifting.
AUTOMATION
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© SAIAG 2001 Page 4 / 17
4 Control panel (+CP)
In order to be able to work with the column the main switch on the control panel has to be
switched to ‘I’.
The emergency stop switches must be unlocked. The emergency stop switches are located one
on the control panel and one on the operator panel (+OP2).
Further, the control system must be activated with the ‘Supply On’ button on the control panel.
AUTOMATION
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© SAIAG 2001 Page 5 / 17
5 Operator Panel 1 (+OP1 on Control Panel)
5.1 Elements on Operator Panel 1
The operator panel is located by the lifting column (outside the blending room) and has the
following operating devices and display units:
Element Description
This button turns on the control system. The “LAMP TEST” function
Illumination Push is activated if the button is pressed for more than 1 second. The
Supply ON
Button white function carries on for a further three seconds once the button has
been released.
Supply OFF Push Button red This button turns off the control system
It lights up when the lift motor is overloaded, and can be reseted by

Illumination Push
Overload Reset pressing this button. The Operator Panel must also reseted
Button red
(pushing ACK) too.
Push Button
Raise to raise the lifting column
green
Push Button
Lower to lower the lifting column
green
Push Button
Inverting to 0° to invert the lifting column to 0°
green
Push Button
Inverting to 180° to invert the lifting column to 180°
green
Push Button
Clamp Unlock to unlock a container. This is only possible in ‘Max. Lift’ Position.
green
Illumination Push to lock a container. This is only possible in ‘Max. Lift’ Position. Is
Clamp Lock
Button green the container locked, so lights up this Button.
Blending Signal Lamp

Is the ‘Blending Position’ OK, so lights up this Lamp.
Permitted white
This indicatorlight is activated in case of an overload, if a motor
Fault Signal lamp red protection switch was triggered or for a other fault, and can be
acknowledged by pressing the ‘ACK’-button on the Operator Panel.
Emergency
Emergency Stop This push button stops immediately all operations
Push Button
Display is needed to set blending parameters into the PLC
OP7 Display (programm number, programm date, blending speed, blending
time)
The operator panel consists a text display with 4 lines. Every line contains max. 20 characters.
AUTOMATION
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© SAIAG 2001 Page 6 / 17
5.2 Functions of Operator Panel 1
Activating the Emergency stop will stop all operations immediately (fail safe). On release of
button the operation will continue where it has stopped.
5.2.1 Ground position Lifting Column
Step Sequence
1.0 Set power isolation switch (Main switch) on control cabinet to ‘I’
Column in Ground Position (‘Inverting stop 0°’ (LS10), Lifting stop ‘Load/Unload’ (LS1))
1.1
(Parked position)
1.2 Press ‘ACK’ button on Operator Panel 1 to acknowledge any faults
5.2.2 Load Operation
2.1 Place Container beteen admisson of blending column
2.2 Press ‘Raise’ to lift the container to ‘Max. Lift Position’
2.3 Press ‘Clamp Lock’ to secure the container, button have to lights up
2.4 Press ‘Lower’ to lower the container to ‘Blending Position’

Start with Blending Operation (chapter 5.3).
2.5
During the blending process it is prohibited to enter the blending room.
AUTOMATION
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© SAIAG 2001 Page 7 / 17
5.2.3 Unload Operation
3.1 After the Blending Operation
3.2 Press ‘Raise’ to lift the container to ‘Max. Lift Position’
3.3 Press ‘Clamp Unlock’ to unlock the container, button ‘Clamp Lock’ have to lights off
3.4 Press ‘Lower’ to lower the container to ‘Load/Unload Position’
3.5 Remove Container
5.2.4 Picture 1: Blending not possible

If the blending Position isn’t reached, one of the following messages appears:
Loading Position
Blending not
possible
Picture 1a
Blending Position
Blending not
possible
Picture 1b
Notes:
· The Lifting stop ‘Blending’ is reached, but not the others positions (‘Inverting stop 0°’,
‘Cantainer Locked’)
Undefined Position
Blending not
possible
Picture 1c
AUTOMATION
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© SAIAG 2001 Page 8 / 17
5.3 Blending Operation
The blending time and the blending speed can be set on the operator panel OP1. Before these
parameters can be entered the following conditions must be satisfied:
- Lifting column in blending position (‘Blending Permitted’ light up)

- Indication lamp on OP1 “Ready for blending” is illuminated (HBLON)
- Inverting position is 0° (LS 10)
5.3.1 Picture 2: Blending permitted
Blending Permitted
Area Secured
>>
Picture 2
5.3.2 Picture 3: Select Program Number
Program 1
Change Prog
<< | >>
Picture 3
Notes:
· Press ‘SHIFT’ and afterwards • or ‚ to select the program number. Press ‘ENTER’ to
set program number
· Press ’F2’ to change the program paramters (first select program number) and picture
10 will appear
5.3.3 Picture 4: Blend Speed / Time
Blend rpm Set: 8

Time Set: 11m 20S
<< Start
Picture 4
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© SAIAG 2001 Page 9 / 17
5.3.4 Picture 5: Time actual / Time remaining
Time act: 5m 10s

Time rem: 6m 10s
STOP
Picture 5
Notes:
· The blending process can be interrupted by pressing ‘F3’
· If the blending time has finished, picture 6 will follow
5.3.5 Picture 6: Turning to zero position
Turning to Zero
Position
PLEASE WAIT
Picture 6
Notes:
· This step cannot be interrupted (with Emergency stop is it possible)
5.3.6 Picture 7: Blending completed
Blending Completed
Speed: 8rpm
Time: 11m 20s
<<
Picture 16
Notes:
· Pressing ‘F1’ brings you back to picture 2. The blending process can be started again if
necessary
AUTOMATION
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© SAIAG 2001 Page 10 / 17
5.4 Special Cases
5.4.1 Picture 8: Blending stopped

If the blending process is interrupted while picture 5 is activated the following display will
appear:
Blending Stopped
Time act: 7m 15s
Time rem: 4m 5s
Start End
Picture 8
Notes:
· Press ‘F2’ will continue the process
· Press ‘F4’ will display picture 6
5.4.2 Picture 6: Turning to zero position
Turning to Zero
Position
PLEASE WAIT
Picture 6
Notes:
· This step cannot be interrupted (with Emergency stop is it possible)
5.4.3 Picture 9: Blending aborted
After turning to zero position has completed picture 9 appears
Blending Aborted
Speed: 8rpm
Time: 7m 15s
<<
Picture 9
Notes:
· Pressing ‘F1’ brings you back to picture 2. The blending process can be started again if
necessary
AUTOMATION
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© SAIAG 2001 Page 11 / 17
5.4.4 Picture 10: Set Blending Program Parameters
Set Blend Parameters

Program Name:
Program No. 1
<<
Picture 10a
Notes:
· Press ‘SHIFT’ and afterwards • or ‚ to select the letter or sign of program name („
next positon, ƒ previous position). The ‘SHIFT’ button remains switched on and by
pressing again it switched off. A yellow LED shows the status of ‘SHIFT’ function.
· Press • or ‚ to select the next paramter (‘SHIFT’ must be switched off)
· Pressing ‘F1’ brings you back to picture 3
Set Blend Parameters

Date: MM.DD.YY
<<
Picture 10b
Notes:
· Press ‘SHIFT’ and afterwards • or ‚ to select the letter or sign of program date („
next positon, ƒ previous position). The ‘SHIFT’ button remains switched on and by
pressing again it switched off. A yellow LED shows the status of ‘SHIFT’ function.
· Press • or ‚ to select the next paramter (‘SHIFT’ must be switched off)
Speed: 8rpm
Time: 11m 20s
<<
Picture 10c
Notes:
· Enter the blend speed (2-10rpm), blend time minutes and blend time scounds (0-59s)
with the numeric buttons
· Press „, •, ƒ or ‚ to select the next paramter (‘SHIFT’ must be switched off)
AUTOMATION
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© SAIAG 2001 Page 12 / 17
6 Operator Panel 2 (+OP2)
6.1 Elements on Operator Panel 2
The operator panel is located on the lifting column and has the following operating devices:
Element Description
Push Button
Raise to raise the lifting column
green
Push Button
Lower to lower the lifting column
green
Emergency
Emergency Stop This push button stops immediately all operations
Push Button
6.2 Functions of Operator Panel 2

Activating the Emergency stop will stop all operations immediately (fail safe). On release of
button the operation will continue where it has stopped.
‘Lower’ and ‘Raise’ is only possible in case of there’s no blending startet.
AUTOMATION
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© SAIAG 2001 Page 13 / 17
7 Errors
Following you’ll see all possible error messages.
Reacts the plant not by press buttons, then press the three buttons ‘Raise’, ‘Lower’ and
‘Inverting to 0°’ together. The actual blending time is lost. Is this problem several times so
contact the technical support.
7.1 General Faults
7.1.1 Error 1: Emergency Stop
FAULT GENERAL
EMERGENCY STOP
Press ACK
Error 1
Reason:
· At least one or both emergency stop push button was pressed
Reset:
· Check all emergency push buttons and unlock them
· Press “ACK” on OP1 to reset the error message on display
7.1.2 Error 2: Air Pressure not OK
FAULT GENERAL
AIR PRESSURE NOT OK
Press ACK
Error 2
Reason:
· No Air pressure
· Air pressure switch malfunction
Reset:
· Check the air pressure supply and the air pressure switch
AUTOMATION
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© SAIAG 2001 Page 14 / 17
7.1.3 Error 3: Door not closed
FAULT GENERAL
DOOR NOT CLOSED
Press ACK
Error 3
Reason:
· Door was opened in Blending
Reset:
· Close the door
During the blending process it is prohibited to enter the blending room.
AUTOMATION
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© SAIAG 2001 Page 15 / 17
7.2 Lifting Faults
7.2.1 Error 4: Overload
FAULT LIFTING
OVERLOAD
Press ACK
Error 4
Reasons:
· Overload relay of the lifting motor was triggered
· Excess load on clamping system
· Motor is jammed
Reset:
· Check the whole area around the column
· Please check if a mechanical malfunction is present
· Press “Reset Overload“and “ACK” on OP1 to reset the error message on the display
7.2.2 Error 5: Motor/Break not OK
FAULT LIFTING
MOTOR NOT OK
Press ACK
Error 5
Reasons:
· The circuit breaker of the lifting motor or break was triggered
· Motor/break is jammed
Reset:
· Please check if a mechanical malfunction is present
· Press “ACK” on OP1 to reset the error message on the display
AUTOMATION
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© SAIAG 2001 Page 16 / 17
7.3 Blending Faults
7.3.1 Error 6: Motor/FC/Thermistor not OK
FAULT BLENDING
MOTOR NOT OK
Press ACK
Error 6
Reason:
· Malfunction of the frequency converter
· The circuit breaker of the blending motor was triggered
· Thermistor relay triggered
Reset:
· Check frequency converter
· Use the frequency converter manual
· Check all motor terminals
· Please check also if a mechanical malfunction is present
· Press “ACK” on OP1 to reset the error message on the display
· Switch main switch on and off
The Frequency Converter may only be opened and repaired by authorisesd

personnel !
If the error appears several times, please call the help desk
AUTOMATION
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© SAIAG 2001 Page 17 / 17

Operating Instructions: Lift & Blend Column

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OPERATING

Böhringer Disol Columbia

Version issued Vis checked Vis Operating Instructions

Rev. Date: Author: Description:

0.0 21. October 2002 Josua Schaub First issue

Electrical hazard, e.g. when working on live equipment.

Mechanical hazard, e.g. when working on hoists.

Important instructions for safe and fault-free operation.

Version issued Vis checked Vis Operating Instructions

Client: Böhringer Disol Columbia

Object: Lift & Blend Column

Serial No. 025005 / O-Nr. 18899

Version issued Vis checked Vis Operating Instructions

Version issued Vis checked Vis Operating Instructions

It lights up when the lift motor is overloaded, and can be reseted by

Blending Signal Lamp

Version issued Vis checked Vis Operating Instructions

5.2.1 Ground position Lifting Column

5.2.2 Load Operation

2.1 Place Container beteen admisson of blending column

2.2 Press ‘Raise’ to lift the container to ‘Max. Lift Position’

2.4 Press ‘Lower’ to lower the container to ‘Blending Position’

Version issued Vis checked Vis Operating Instructions

3.1 After the Blending Operation

3.2 Press ‘Raise’ to lift the container to ‘Max. Lift Position’

3.4 Press ‘Lower’ to lower the container to ‘Load/Unload Position’

3.5 Remove Container

5.2.4 Picture 1: Blending not possible

Version issued Vis checked Vis Operating Instructions

- Lifting column in blending position (‘Blending Permitted’ light up)

5.3.1 Picture 2: Blending permitted

5.3.2 Picture 3: Select Program Number

5.3.3 Picture 4: Blend Speed / Time

Blend rpm Set: 8

Version issued Vis checked Vis Operating Instructions

Time act: 5m 10s

5.3.5 Picture 6: Turning to zero position

5.3.6 Picture 7: Blending completed

Version issued Vis checked Vis Operating Instructions

5.4.1 Picture 8: Blending stopped

5.4.2 Picture 6: Turning to zero position

5.4.3 Picture 9: Blending aborted

After turning to zero position has completed picture 9 appears

Version issued Vis checked Vis Operating Instructions

Set Blend Parameters

Set Blend Parameters

Version issued Vis checked Vis Operating Instructions

6.2 Functions of Operator Panel 2

Version issued Vis checked Vis Operating Instructions

7.1 General Faults

7.1.1 Error 1: Emergency Stop

7.1.2 Error 2: Air Pressure not OK

Version issued Vis checked Vis Operating Instructions

During the blending process it is prohibited to enter the blending room.

Version issued Vis checked Vis Operating Instructions

7.2.1 Error 4: Overload

7.2.2 Error 5: Motor/Break not OK

Version issued Vis checked Vis Operating Instructions

7.3.1 Error 6: Motor/FC/Thermistor not OK

The Frequency Converter may only be opened and repaired by authorisesd

Version issued Vis checked Vis Operating Instructions

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