Slide Gate/Auger Gravimetric Batch Blenders With Mitsubishi Controller Part Number: A0567659 Bulletin Number: SM1-605M.1 Effective: 6/10/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid. The invoice number and date or purchase order number and date must be supplied.
Table of Contents CHAPTER 1: CHAPTER 1: SAFETY ......................................... 7 1-1 1-2 1-3 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual .....................................................................7 Warnings and Precautions .......................................................................................... 9 Responsibility ..................................................
3-6 3-7 Re-Mix Timer .......................................................................................................49 Weigh Hopper Dump Time ..................................................................................50 Weigh Hopper Dump Delay Time........................................................................50 Weigh Hopper Dump Cycle .................................................................................50 Mixer Options ...................................................
7-5 7-6 Slide Gate Gravimetric Batch Blending Systems ................................................79 Auger Gravimetric Batch Blending Systems........................................................80 Blender Identification (Serial Number) Tag ............................................................... 90 Technical Assistance................................................................................................. 90 Parts Department ...........................................................
Chapter 1: Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your Gravimetric Batch Blender. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.
Gravimetric Batch Blender Safety Tags Tag Description Tag Description Pinch Point Slide Gate Read Operation & Installation Manual Shear Point Rotating Mixer Earth Ground High Voltage Inside Enclosure PE Shear Hazard Rotating Auger Gravimetric Batch Blenders w/Mitsubishi ControlChapter 1: Safety Protected Earth Ground Lifting Point 8
1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machine should become familiar with its operation as described in this manual. Proper operation of the machine promotes safety for the operator and all workers in its vicinity.
Operator Responsibility The operator’s responsibility does not end with efficient production. The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations. Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through a casual attitude toward machinery formed over a period of months or years. Your employer probably has established a set of safety rules in your workplace.
• Clean the blender and surrounding area DAILY, and inspect the machine for loose, missing or broken parts. • Shut off power to the blender when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for slide gate and auger blenders of various blending rates and specifications. See Figure 1 below for a list of available models. Figure 1: Models Covered by this Manual Slide Gate Blenders • 450 • 900 • 2500 • 4000 • 5000 Auger Blenders • 002 • 012 • 030 • 060 Model numbers are listed on the serial tag.
2-3 Typical Features & Components Mechanical Features Slide Gate Blenders • Exclusive diamond design slide gate metering assemblies meter a large range for free flowing pellet materials • Slide gate stroke limiting restrictors provided for accurate metering of minor ingredients • Electro-polished 304 SS stainless steel weighing and blending components • Removable stainless steel weigh hopper • Mild steel material supply hoppers with clean-out doors and material drains Auger Blenders • Efficient Opti-Mixer®
Controller Features • LCD touch-screen interface display operator control panel with 8’ cable • Target vs. actual set point verification • Inventory accumulation for all ingredients • Audible and visual alarms • Auxiliary alarm contact • 50 recipe storage book • Three (3) types of recipe entry procedures available: • Quickset mode (up to 6-component) recipe entry. Color and additives are metered as a percentage of the virgin material. • Percentage mode recipe entry.
Note: The touch-screen panel display on your unit may be slightly different than shown. Slide Gate & Auger Blender System Component Description This section describes the various components of the blending system.
Slide Gate Metering Assemblies (Slide Gate Blenders) Air operated slide gates are provided to meter the majority of pellet ingredients on Slide Gate blenders. Note: The metering range assumes 1/8” diameter free-flowing plastic pellets weighing approximately 35 lbs./cu. ft. This is meant to be an approximate sizing recommendation and can vary with different bulk density resins, pellet configuration, etc. A stroke limiter (included) can be installed on the metering gates to limit their travel.
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 interrupted to the blender, the metering valves will return to the closed position, to prevent material from over-filling the weigh hopper/mix chamber.
Weigh Hopper The weigh hopper on the Slide Gate/Auger 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 the lower mix section is uncovered, the valve will open and discharge the batch into the mixer with the existing blended material. The discharge valve is also provided with a quick disconnect so the weigh hopper can be removed for cleaning.
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 controls the flow of air to the valve stack.
Operator Control Panel The operator control panel includes a 8 foot (2.4 m) cable and can be remote mounted (not recommended) adjacent to the blender. The panel can be unplugged and removed if necessary. The controller includes an embedded computer. This design provides excellent blender performance along with an easily replaceable control panel in the unlikely failure of any computer or electronic part. The display menu format is very simple.
Figure 8: Typical Setup Screens Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 22
Figure 9: Typical Operator Screens LOGO Slide Gate/Auger Blender Version: Main 1.
2-4 Options The following is a list of options, which your blender may have 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. Allows control of blender from a second location up to 50 feet (30 meters) away. Mezzanine & Floor Stands. Supports blenders in mezzanine mount and freestanding applications. Take-off Compartments.
Figure 11: Typical Central Blender Layout (Slide Gate Location on Blender) Blender Pneumatic Slide Gate Below Mixer Surge Bin Take-off Compartment Floor Stand 2-5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Gravimetric Batch Blender. This manual is not intended to supersede or alter safety standards established by the user of this equipment.
Fail Safe Operation If a safety device or circuit should fail, the design must be such that the failure causes a “Safe” condition. As an example, a safety switch must be a normally open switch. The switch must be held closed with the device it is to protect. If the switch fails, it will go to the open condition, tripping out the safety circuit. At no time should the safety device fail and allow the operation to continue.
Twist Cap Plug Connected to Each Auger Motor (Auger Blender only) The cap plug must be turned counter-clockwise to loosen and the female end of the cord removed from the motor plug. This disables the motor from turning while the auger unit is being serviced or cleaned. The motor cords are cut to length so they must be disconnected before the auger can be removed from the housing. Disconnect plug before cleaning or servicing motors or augers.
Chapter 3: Installation 3-1 Uncrating the Equipment Slide Gate/Auger Blenders are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Remove crate from around blender. 2. Secure strap of proper lifting capacity to both lifting lugs (See Figure 15 below.). Caution! Use approved safety straps or chains to lift the blender at the marked lifting points. 3. Lift blender until strap is taut. 4. Remove bolts attaching bottom of blender to shipping skid. 5.
Machine Mount In a machine mounting application of the Slide Gate/Auger unit, there are a few items to review before placement and mounting of the blending system begins. First, verify the machine flange dimensions match the Slide Gate blender flange (if the optional pre-drilled holes were ordered). The Slide Gate blender can also be equipped with an optional cast throat section with a drain port. This will bolt under the bottom plate of the blender.
Mezzanine Mount In a mezzanine mount application, review the following items before installation begins. First, verify the Slide Gate/Auger mounting locations match the mezzanine supports. Verify that the mezzanine is capable of supporting the blender with a full load of material and vacuum loading equipment installed. Note: While in operation, the Slide Gate/Auger blender applies horizontal and vertical pressures to the mounting flange.
Floor Mount (Central Blender) In a floor mounting application, ensure adequate clearance for all blender operations and maintenance. The operator and maintenance personnel must have access to parts of the blender. If necessary, it is the customer’s responsibility to provide adequate, safe work platforms around the blender to meet state and local safety codes. Using proper lifting equipment, lift the Slide Gate/Auger blender in place.
Mechanical Installation The installation procedure should be used as a general guideline for the proper installation steps required to install the Slide Gate/Auger blending system. 1. Lift blender and position over machine throat or floor stand. 2. Set in position and secure by tightening four bolts. 3. Remove lifting strap. 4. Mount the material conveying system receivers on the top of the blender supply hoppers. 5. Align the weigh hopper on the load cell brackets.
3-4 Pneumatic Installation The Slide Gate/Auger blending system uses plant-supplied 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 should not be used unless air dryers are installed on the compressed air supply. In this situation, an oiler may be required on the blender to keep the air cylinder seals lubricated.
3-5 Set-up This section will discuss the mechanical setup and control system setup of the Slide Gate/Auger blending system. After reading this section, you should be familiar with the mechanical setup and the electronic control setup of the blending system. Stroke Limiters for Metering Gates Stroke limiters are supplied on components 1 through 4 with all Slide Gate blenders to allow standard metering gates to meter small amounts of low percentage additive materials.
Load Cell Adjustment The mechanical setup of the Slide Gate/Auger blending system involves the adjustment of the weigh hopper load cells (Please refer to the figure below). This figure illustrates the proper adjustment of the load cell mechanical stop bolt. The setting for the positive stop is necessary to prevent the load cell from being “over-ranged” by excessive loading on the weigh hopper. The setting for the load cell stop is forty thousandths of an inch maximum (.040”).
Final Connections 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 water trap, and lubrication unit, if required. Verify that 60 psi (4.14 bar) of clean, dry compressed air is supplied to the blender.
If not, the blender can be reconfigured for Quickset Recipe, Percent, or Parts by entering the Setup menu and pressing the Recipe Format key. Then select the mode following the key prompt on the screen. To access the Setup Menu to change the Recipe Mode and other controller features, refer to the following pages of this manual. Controller Setup This section describes the proper setup of the Slide Gate/Auger blending system control parameters.
The Recipe Format screen allows the user to change many parameters concerning the way that the recipe is entered by the operator. It is accessed by touching the manufacturer’s icon on either the Recipe screen or the Inventory Screen. The user must enter in the User Password to gain access (see User Password Setup for details.).
Figure 21: Example calculations of a five (5) -component blend in “Quickset” mode 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. Total available: 100.00% Regrind: 30.00% Balance: 70.00% Virgin + Additive 1 + Additive 2 + Additive 3 = 70.00% Virgin + (5% of virgin) + (2% of virgin) + (1% of virgin) = 70.
“Parts” Mode (Often used in Compounding Applications) The “Parts” recipe entry mode lets the operator enter in values based on a parts ratio rather than a percentage. Each entry can be up to 999.99 and the total of all hoppers does not have to be 100. After all values are entered, the total parts are calculated. The individual hopper target is then calculated based on each hopper’s entered parts. These parts represent ratios of the total batch.
takes effect. This order can be changed while the blender is making a batch without affecting the current running batch. Note: All feeders must be in the metering order. Do not have the same metering order number assigned to two feeders at the same time as the control will not accept the settings. Batch Size Menu The Slide Gate/Auger blending system is a gravimetric batching system. The blender will weigh a preprogrammed batch of material each cycle.
central blending application. In either case, the manufacturer has provided a means to automatically stop the blending system when the blended material has reached a preset total blended weight. This is known as Inventory Shutdown. When the Inventory Shutdown value is reached, the blender will finish the current batch of material. It will then stop and display to the operator that the inventory value has been reached. Additionally, it will flash an alarm and wait for operator attention.
Every Second Batch In the every second batch mode, the Slide Gate/Auger blending system will weigh each component of the batch during one cycle and then run all components simultaneously the next cycle on a time basis that was learned during the weigh cycle. After an initial learn cycle, the blender will weigh every other batch and then run volumetrically timed metering every other batch. This allows for greater throughput of the blender.
modify the new recipe without affecting the blender until they hit the “Accept New Recipe” button. 7. Recipe entry is complete. 8. To start the blender press “Push to Start or Stop” button. Note: ***Other questions regarding controller features are answered in the Service Supervisor Section at the back of this manual.*** Printer Features The Slide Gate/Auger blending system may be equipped with a printer, so a printer menu is available to the operator.
• Clear Inventory • Display Time & Date Batch Interval or Timed Interval Printout The Batch Interval item under the Recipe menu works in conjunction with the Auto Print Interval to set the number of batches between printouts or on a timed interval between printouts. Time Printout When entering the Report Setup menu, the operator will have to decide whether the printout should be timed and by the number of batches between each printout.
ensure that the reported inventory totals are accurate. Remember that in most cases a bad calibration is worse than no calibration. Standard Calibration on a blender equipped with an OptiMix style mixer (Recommended only if the calibration is out of spec) 1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413”, then press the “Enter˝ key. 2. Touch “Calibration” and then “Scale Calibration”. 3. Remove the weigh hopper, clean it out and press “OK”. 4.
Why Blender Calibration is Necessary The load cells on the Slide Gate/Auger blender are FACTORY CALIBRATED. Since the load cells can be subject to shock loading during shipping, moving, etc., we recommend that they be recalibrated. The heart of the blending system is the load cell with the supply calibration weight. They monitor the weight off each ingredient added to the blender weigh hopper.
1. Once in “Scale Calibration”, enter in the scale calibration weight value stamped on the side of the weight. 2. The controller will prompt you to remove the weight hopper and press OK. 3. After touching OK, the controller will display “PLEASE WAIT...” 4. Next, the controller will ask you to hang the calibration weight on the right loadcell bracket (loadcell A) and press OK. 5. The controller will ask you to hang the calibration weight on the left loadcell bracket (loadcell B) and press OK. 6.
the feeder. To perform a feeder calibration, the operator must enter the “Feeder Calibration” screen (see menu structure), select a feeder number, then touch “Press Here.” The feeder calibration will start automatically and will notify the operator when complete. If the operator so desires, they can repeat the process by entering in a new feeder number and touching the “Press Here”button.
If the re-mix timer is disabled, the controller will run only a single, timed mix cycle after each dump of the weigh hopper. To view and change the value of the re-mix timer, refer to the “Mixer and Dump Setup” menu. All current values for Mixing and Remixing Times will be shown on this screen. The re-mix timer default value is factory preset at zero.
Mixer Options Press the “Timed/Continuous Mixing” key (In the top right hand corner) when in “Mixer and Dump Setup” screen to set the following options: Timed Mixing Option This mode of operation turns the mixer on only during dumping and during the re-mix time set into the control to jog the mixer during high level mixer operation.
Enable or Disable Retries Select a Feeder to Configure Enable or Disable Alarms Change the Alarm Silence Delay Go back to Setup Directory 3. Select a feeder (1-6) by touching 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,” and Out of Material Alarm Silence Delay (060 seconds) settings.
• Calibration Error, Clean out hopper and check calibration: This alarm indicates that the maximum 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 exceeded, then an alarm will appear. This alarm is most commonly caused by a build up of sticky material in the weigh hopper and can be corrected by simply cleaning out the weigh hopper.
• Inventory Cleared: This is only logged in the Alarm Log and does not cause a popup message or audible alarm. Each time the inventory is cleared, the time and date are logged to the Alarm Log. An alarm will sound and a screen will pop up when Auto. Inventory Shutdown has been reached. • E-Stop Screen: The blender is equipped with an E-stop switch that removes the power from all mechanical outputs. The E-Stop Screen appears along with an audible alarm whenever the E-Stop is activated.
4. Press the number next to “sec” on the “Remix Time” to set “Re-mix” off time. This allows the mixer to come on between batches if the blender cycle time is very slow, i.e. if you want the mixer to come on every minute, set this to 60 seconds. If you don’t want to use this function, set the time to “0”. 5. Press the number next to “sec” on the “Dump Time” to set your dump time (A value between “1” and “999” will need to be entered.). This feature is the amount of time required to empty the batch hopper.
Chapter 4: Operation 4-1 Start-up General Operation The general operation of the Slide Gate/Auger blending system is as follows: Once the system is properly installed and set up, the system will be ready for operation. Please see the Installation and Setup chapter in this manual for further information. Once the Slide Gate/Auger blending system is powered on, the unit will display the recipe screen (the recipe format should be in “Quickset” recipe mode).
The blender monitors the operator’s entries and determines if the recipe entered is valid before allowing the operator to accept the new 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 operator of the problem. The “Accept New Recipe” button is only shown if the recipe is valid and different from what is currently running on the blender.
4-2 Controller Description & Operation Display Description (LCD) The Slide Gate/Auger 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 above.
Slide Gate & Auger Blender Control System Menu Structure “Recipe” Page (Start) ¾ ¾ ¾ ¾ ¾ ¾ ¾ Change Recipe Values by touching the number you wish to change Touch “Accept New Recipe” button after you’ve made the desired changes Start or stop the blender by touching the “Push to Start” or “Stop” button Access “Recipe Book” Page Access “Clean Out” Page Access “Inventory Page” Access “Setup” Page “Recipe Book” Page ¾ ¾ ¾ ¾ ¾ Save the running recipe to the book Delete a stored recipe Load a stored recipe Era
Control Functions The objective of this section is to familiarize the reader with the Slide Gate/Auger blender recipe menus, run mode operation, run mode menus and displays. Upon the completion of this section, the reader will be familiar with the recipes and run mode displays that are available on one blender, including the recipe book and recipe storage facilities. Other items covered in this section are optional printer functions and report generation capabilities of the Slide Gate/Auger blending system.
Save Running Recipe to the Book The save current recipe to book function allows the operator to save the contents of the current recipe to the recipe book under a desired number. Upon selecting this function, the operator will be prompted for a reference recipe number. This may be any number from 1 to 50. The assigned recipe number will be used for all further references to this recipe until deleted. The operator should be familiar with the recipe numbers used.
Feeder Clean Out Any feeder in the Slide Gate/Auger blending system can be emptied and refilled with a different material. To do a feeder clean out, the operator has to press the “Clean Out” icon key from the recipe screen (the first screen that appears on power up). 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 open weigh hopper dump door will allow the material to drop into the mixer section of the blender. If the 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 the high-level sensor in the mixing chamber is uncovered to start another weigh cycle. (Unless the Re-Mix timer is set to a value other than 0 and times out to restart the mixer to run for another mix cycle.
5. If you want to catch the color, use a small plastic pail or chute to collect the material from the slide gate assembly. Reach up inside the blender to the color slide gate and push it open. At this point, there should be no air pressure on the blender, and the slide gate should move easily. Drain the color out in the bucket.
Standard Run Time Displays While the blending system is in operation, there are a couple of displays available to the operator. These displays are selected simply by pressing the “NEXT” key when the unit is running. The default display shown when the blender is in run mode is the Recipe Screen. The Recipe Screen indicates by feeder number, the amount of material metered into the weigh hopper assembly by that particular feeder. This display is updated after each component dispenses its specified amount.
4-3 Shutting Down the Blender The Slide Gate/Auger Gravimetric Blender can be stopped in one of two ways: 1. To immediately stop the blender, the operator can touch “Abort Current Batch.” This will cause the blender to stop making the current batch immediately. Obviously, if the blender is stopped in this method then the current batch will not be completed properly. 2. If the operator desires to complete the current batch of material, then he can wait until the Inventory Shutdown value is reached.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule 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 checklist below contains a list of items which should be inspected and/or replaced to keep your blender operating at peak efficiency. Perform each inspection at the regular intervals listed below.
5-2 Preventative Maintenance Our blenders need periodic maintenance to provide long dependable service. Check these elements regularly: • Check functionality of safety circuit daily. • Maintain proper air pressure and drain water from trap assembly on regulator – as required. • Periodically lubricate slide gate rails. 5-3 WARNING! Always remove plug and disconnect power before servicing blender. WARNING! Always read operating manual before operating or servicing blender.
Input Signals to Programmable Controller The Slide Gate/Auger blending system has two main input signals that it uses from the blending process: the mix hopper high level signal and the weigh hopper load cells. This, of course, does not include the operator touchscreen input. The mix hopper high level signal is generated by a proximity level sensor located in the right hand portion of the mixer chamber (viewing from the mixer door). Load cells require +10 volts DC to operate.
Pneumatic System Maintenance The Slide Gate/Auger blending system uses plant-supplied compressed air to operate the metering and dump valves on the blender. It is the user’s responsibility to provide CLEAN AND DRY air for the blender to be connected to. The air supply should be filtered through a 5 micron air filter and have a water separator installed. Oil should not be used unless air dryers are installed on the compressed air supply.
Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service. The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated.
Problem PLC Module Loaded Corrective action Normal after a software upgrade. Follow on-screen instructions. Check the input power. Verify that 110 volts (or 220 volts) are ±10%. This voltage must remain constant with all the motors starting and stopping. Insure that the blender is on a “clean” circuit that does not have other equipment on it. If the power is known to be intermittent and have problems, set up the unit to run in “AutoStart” mode. See the factory setup sheet at the end of this manual.
Problem Recorded Inventory Totals don’t match what I’ve actually used Corrective action Check the blender’s scale calibration and verify that the batch hopper is not overfilling. If the hopper is overfilling, adjust your batch size. If this is correct, then you are probably not accounting for material scrap or other items in your process. Some error can be introduced by not weighing every batch. Check the Recipe Page. Max Hopper Weight Exceeded Alarm continues to re-occur.
Problem Mixer won’t shut off and runs continuously. Corrective action Check the Mixer and Dump Setup to see if the mixer is configured 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 control panel on the SSR for the mixer motor.
Problem I can’t calibrate the Scale without an error message. I can’t calibrate the feeder without an error message. Corrective action This Is caused by the difference in bits not being large enough. Using the Direct Scale Readout, examine current loadcell bits with and without the calibration weight. If the bits do not change significantly, then check for pellets jamming the loadcells and check the loadcell circuit. You might have a bad loadcell.
Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YEAR PARTS AND LABOR WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions, as set forth in the operating manuals for such equipment.
applicable federal and state law, but not by the United Nations Convention on Contracts for the Sale of Goods. Customer Responsibilities Any sales, use, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser. 7-2 Technical Specifications Annex B Information The following design information is provided for your reference: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
28. There are no frequent repetitive cycles that require manual controlrepetitive functions are automatic while the blender is operating. 29. An inspection report detailing the functional test is included with the blender. 30. The machine is not equipped with cableless controls. 31. Color-coded (harmonized) power cord is sufficient for proper installation.
7-3 Drawings & Diagrams Typical Slide Gate Model Assembly Overview 7-4 Spare Parts List Slide Gate Gravimetric Batch Blending Systems Model 450 Part No. Description 53292 Air Cylinder (weigh hopper dump) 10220 Mixer Agitator (Opti-Mixer) 2kg Load Cell 63881 Mixer High Level Sensor 35448 Slidegate Air Cylinder (3” stroke) A0565882 Calex Module A0565881 (PLC back base) A0565885 Touch Screen Interface A0542200 1.5 Amp Fuse A0565892 3.
Model 900 Part No. Description 35450 Air Cylinder (weigh hopper dump) 10207 Mixer Agitator (Opti-Mixer) 5kg Load Cell 63881 Mixer High Level Sensor 35448 Slidegate Air Cylinder (3” stroke) A0565882 Calex Module A0565881 (PLC back base) A0565885 Touch Screen Interface A0542200 1.5 Amp Fuse A0565892 3.0 Amp Fuse Model 4000 & 5000 Part No.
Model 012 with Opti-Mixer™ Part No. Description 35450 dump cylinder 35463 valve stack (1) 35435 pressure indicator 35437 safety control valve 5kg Load Cell 10207 mix agitator 63881 Mixer High Level Sensor 53361 1/6hp mix motor 55212 2-amp fuse A0565882 Calex Module A0565881 (PLC back base) A0565885 Touch Screen Interface A0542200 1.5 Amp Fuse A0565892 3.
Model 060 with Optimixer™ Part No. Description 53243 dump cylinder 35476 valve stack(5) 35435 pressure indicator 63881 Mixer High Level Sensor 53280 1/2hp mix motor 55216 10-amp fuse 20kg Load Cell 59643 25 amp relay A0565882 Calex Module A0565881 (PLC back base) A0565885 Touch Screen Interface A0542200 1.5 Amp Fuse A0565892 3.
Model 060 with Common Feeder Components 51450G 1/15hp 70rpm 51449G 1/15hp 97 rpm 51453G 1/15hp 139 rpm 08236-1 3/4" auger 08237-1 1" auger 08238-1 1-5/8" auger 08239-1 2" auger 51440G 1/6hp 156rpm 08317-1 3" auger 08318-2 3-1/2" auger Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix 83
Typical Mixer Section (Front) Typical Opti-Mixer™ - Front Assembly Detail Location In Drawing 01 02 03 04 05 06 07 08 09 Part Number Description Nameplate and indicator mounting plate Nameplate Upper polycarbonate Opti-Mixer™ door Door clamp “Caution” label Lower stainless steel Opti-Mixer™ door Mixer agitator door bushing Door hinge Door hinge base Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix 84
Typical Mixer Section (Rear) Typical Opti-Mixer™ - Rear Assembly Detail Location In Drawing 10 11 12 13 14 15 16 17 Part Number Description Opti-Mixer™ back plate Cover plate Back control panel Cover plate Proximity sensor (Mixer “high” level) Mixer proximity sensor mounting plate Mixer gear motor Mixer agitator shaft coupling Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix 85
Typical Mixer Frame Typical Opti-Mixer™ Frame Assembly Location In Drawing 18 19 20 21 22 23 24 25 Part Number Description Hinge mounting bracket Mixer door clamp Load cell cover Opti-Mixer™ top plate Opti-Mixer™ frame Warning label Opti-Mixer™ frame side panel Hinge mounting bracket Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix 86
Typical Gate Assembly Typical Slide Gate Diamond Gate Assembly Detail Location In Drawing 28 29 30 31 32 33 34 35 36 37 38 Part Number Description Slide gate guide rod Stainless steel gate assembly base Slide gate stop (stroke-limiter) Retaining clip Slide gate air cylinder Slide gate air cylinder pneumatic connector fitting Slide gate air cylinder pneumatic barb fitting Slide gate assembly material chute (deflector) Notice (warning) label Pin Diamond v-gate (metering slide gate) Gravimetric Batch Blende
Typical Supply Hopper Typical Slide Gate-014 Series Hopper Assembly Detail Location In Drawing 40 41 42 43 44 45 46 47 48 49 50 51 Part Number Description Mild steel hopper cover Hopper insert (square to diamondpolyurethane) Mild steel hopper Gasketing Polycarbonate access door N/A Polycarbonate hopper sight glass Blow-off tool holder Blow-off tool Drain plug Cleanout door clamp Optional low level proximity sensor mount Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix 88
Typical Weigh Hopper Typical Weigh Hopper & Load Cell Detail Location In Drawing 52 53 54 55 56 57 58 59 60 61 62 63 Part Number Description Left weigh hopper bracket Inside mixer plate Weigh Hopper Weigh hopper discharge air cylinder pneumatic connector Weigh hopper discharge air cylinder Weigh hopper discharge air cylinder mounting bracket Weigh hopper discharge hinge pin (bolt) Weigh hopper discharge flapper Right weigh hopper bracket Spacer Load cell(s) Load cell mounting plate Gravimetric Batch Blen
7-5 Blender Identification (Serial Number) Tag (Located on back of mixing chamber) Logo XXX Series Blender Model Number xxx-xxx Max Blending Capacity 318 KG/HR 220V Serial Number 060701R 1Ǿ Date of Manufacture 06/2004 4.5A Over-current Protection Device (s) 4.5A Total Frequency 50/60Hz Compressed air supply 4.
Chapter 8: Addendum 8-1 Service Supervisor Information Note: This section of the manual should not be used by untrained personnel – blender controller and/or program can be compromised! Note: Hidden, programmable features and hidden menu pages should not be made available to floor operators. These pages include the Service Supervisor Information addendum located in this section.
time as long as the target weight has not been changed. This allows you to open the gate for several feeds using the same amount of time. You can then record the Dispensed Grams and plot the standard deviation of the gate. The other purpose of this screen is to verify that the dispensed weight displayed is correct. You can perform a meter and then pull the weigh hopper to weigh the material on a gram scale. The value on the screen should match the measurement on the gram scale.
Go back to Engineering Only Directory 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 feeder and then follow instructions.
Feeder Setup This screen allows you to modify the type of each feeder. In most cases, the 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 blender is configured in “Quickset Mode” then one hopper must be configured for Regrind and only one hopper must be configured for Virgin material. If this is incorrect, a message will be given on the Recipe Screen.
Alarm Setup This screen allows the user to configure the feeder type for each feeder; configure whether a feeder will retry during the metering of a batch, and enable or disable the “Out of Material” alarm for any feeder. If a hopper is set to “No Retry” then the blender will continue to meter the rest of the batch even if this hopper runs out of material.
Programmable Features (continued) After all selections are made: • Keep pressing the “Done” key until the unit returns to the Recipe menu. Note: Programmable features should not be accessed by inexperienced operators or inexperienced plant personnel. Unauthorized changes may prevent the blender from operating properly and may void part or all of the warranty.
