Mitsubishi A0567659 Specifications

Slide Gate/Auger Gravimetric Batch Blenders
With Mitsubishi Controller
Part Number: A0567659
Bulletin Number: CM1-605M.1
Effective: 6/10/05
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2004
All rights reserved.
Please note that our address and phone information has changed.
Please reference this page for updated contact information.
These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.
Parts and Service Department
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering
design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone
or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list
is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.
For immediate assistance, please contact:
•
North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and cooling
and automation. For size reduction: +1 (800) 229-2919.
North America, emergencies after 5pm CST (847) 439-5855
North America email: acsuscanadacustserv@corpemail.com
•
Mexico, Central & South America
Email: acslatinamericacustserv@corpemail.com
•
Europe, Middle East & Africa +48 22 390 9720
Email: acseuropecustserv@corpemail.com
•
India +91 21 35329112
Email: acsindiacustserv@corpemail.com
•
Asia/Australia +86 512 8717 1919
Email: acsasiacustserv@corpemail.com
Sales and Contracting Department
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the
name of the sales representative nearest you.
Let us install your system. The Contract Department offers any or all of these services: project planning; system packages
including drawings; equipment, labor, and construction materials; and union or non-union installations.
For assistance with your sales or system contracting needs please Call:
North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST
Europe/Middle East/Africa +48 22 390 9720
India +91 21 35329112
Asia/Australia +86 512 8717 1919
Facilities:
ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com
United States:
ACS Schaumburg – Corporate Offices
1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804
ACS New Berlin – Manufacturing Facility
th
2900 S. 160 Street
New Berlin, WI 53151
Phone : +1 262 641 8600
Fax: + 1 262 641 8653
Asia/Australia:
ACS Suzhou
109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: +86 512 8717 1916
Europe/Middle East/Africa:
ACS Warsaw
Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: +48 22 390 9724
India
ACS India
Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: +91 21 35329112
Fax: + 91 20 40147576
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.
Notify the transportation company’s local agent if you discover damage
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 (800) 233-4819; for all other countries, call
our international desk at (630) 475-7491. Have the order number and item number available.
Hold the items until you receive shipping instructions.
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
Gravimetric Batch Blenders w/Mitsubishi Control
ii
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.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty 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 returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
Gravimetric Batch Blenders w/Mitsubishi Control
iii
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 ............................................................................................................ 10
General Responsibility.........................................................................................10
Operator Responsibility .......................................................................................11
Maintenance Responsibility.................................................................................12
Reporting a Safety Defect ...................................................................................12
CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 13
2-1
2-2
2-3
2-4
2-5
Models Covered in This Manual................................................................................ 13
General Description................................................................................................... 13
Accessories .........................................................................................................13
Customer Service................................................................................................13
Typical Features & Components ............................................................................... 14
Mechanical Features ...........................................................................................14
Controller Features..............................................................................................15
Slide Gate & Auger Blender System Component Description.............................16
Options ...................................................................................................................... 24
Remote Touch Screen ........................................................................................24
Pneumatic Slide Gate Below Mixer .....................................................................24
Safety Devices and Interlocks ................................................................................... 25
CHAPTER 3: INSTALLATION ................................................... 28
3-1
3-2
3-3
3-4
3-5
Uncrating the Equipment........................................................................................... 28
Rigging and Placing the Unit ..................................................................................... 28
Site Requirements ...............................................................................................28
Mounting Configuration .......................................................................................28
Mechanical Installation ........................................................................................32
Electrical Installation.................................................................................................. 32
Pneumatic Installation ............................................................................................... 33
Set-up........................................................................................................................ 34
Stroke Limiters for Metering Gates......................................................................34
Weigh Hopper Installation (Slide Gate Models only) ...........................................34
Load Cell Adjustment ..........................................................................................35
Final Connections................................................................................................36
Controller Setup ..................................................................................................37
Recipe Entry Formats..........................................................................................37
Printer Features...................................................................................................44
Batch Interval or Timed Interval Printout .............................................................45
Print Inventory .....................................................................................................45
Display Time and Date ........................................................................................45
Blender Calibration ..............................................................................................45
Feeder Calibration (Auger Blenders)...................................................................48
Mix Timer.............................................................................................................49
Gravimetric Batch Blenders w/Mitsubishi Control
iv
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 ......................................................................................................51
Setting Date & Time ............................................................................................51
Feeder Alarm Setup & Flags ...............................................................................51
Network Communications Baud Rate & I.D. Settings..........................................54
Additional settings that usually do not have to be changed:................................54
Initial Startup ............................................................................................................. 55
Shutting Down Blender.............................................................................................. 55
CHAPTER 4: OPERATION ........................................................ 56
4-1
4-2
4-3
Start-up...................................................................................................................... 56
General Operation...............................................................................................56
Quick Start Procedure .........................................................................................56
Controller Description & Operation............................................................................ 58
Display Description (LCD) ...................................................................................58
Control Functions ................................................................................................60
Recipe Book (Storage) Menus ............................................................................60
Feeder Clean Out ................................................................................................62
Standard Run Time Displays...............................................................................65
Shutting Down the Blender........................................................................................ 66
CHAPTER 5: MAINTENANCE ................................................... 67
5-1
5-2
5-3
Preventative Maintenance Schedule......................................................................... 67
Preventative Maintenance......................................................................................... 68
Corrective Maintenance ............................................................................................ 68
Electrical..............................................................................................................68
Internal Components of the Control Panel ..........................................................68
Input Signals to Programmable Controller...........................................................69
Output Signals from Programmable Controller....................................................69
Pneumatic System Maintenance .........................................................................70
CHAPTER 6: TROUBLESHOOTING ........................................ 71
6-1 Introduction .................................................................................................................. 71
CHAPTER 7: APPENDIX .......................................................... 76
7-1 Warranty ....................................................................................................................... 76
Warranty Specifications.......................................................................................76
Warranty Restrictions ..........................................................................................76
Warranty Liabilities ..............................................................................................76
Customer Responsibilities ...................................................................................77
7-2 Technical Specifications ............................................................................................... 77
Annex B Information ............................................................................................77
Slide Gate Blender (-E) Series Specifications .....................................................78
Auger Blender (-E) Series Specifications ............................................................78
7-3 Drawings & Diagrams ................................................................................................... 79
7-4
Spare Parts List......................................................................................................... 79
Gravimetric Batch Blenders w/Mitsubishi Control
v
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 ................................................................................................90
Service Department.............................................................................................90
Sales Department................................................................................................90
Contract Department ...........................................................................................90
CHAPTER 8: ADDENDUM........................................................ 91
8-1
Service Supervisor Information ................................................................................. 91
Programmable Settings .......................................................................................91
Factory Setup Menu (Available Selections).........................................................91
Customer Setup Menu ........................................................................................94
Programmable Features (continued)...................................................................96
Passwords ...........................................................................................................96
Gravimetric Batch Blenders w/Mitsubishi Control
vi
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.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the blender. We can also provide the assistance of a factory-trained technician to help train
your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the Gravimetric
Batch Blender. These instructions are intended to supplement standard shop procedures
performed at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the unit safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your Gravimetric Batch Blender provides
excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. A spare parts list with part numbers specific to your machine is provided
with your shipping paperwork package. Refer to this section for a listing of spare parts for
purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER!
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING!
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
Caution!
CAUTION indicates a potentially hazardous situation or practice that,
if not avoided, may result in minor or moderate injury or in property
damage.
Gravimetric Batch Blenders w/AB Control
Chapter 1: Safety
7
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.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Keep fingers away from slide gates, augers, clean-outs, and calibration hatches.
Automatic operation may start unexpectedly, A PINCH HAZARD CAPABLE OF
CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power and compressed air before servicing or maintaining
the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
Gravimetric Batch Blenders w/AB Control
Chapter 1: Safety
9
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.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No matter who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
Gravimetric Batch Blenders w/Mitsubishi ControlChapter 1: Safety
10
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. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.
REMEMBER:
• NEVER place your hands or any part of your body in any dangerous location.
• NEVER operate, service, or adjust the blender without appropriate training and first
reading and understanding this manual.
• NEVER try to pull material out of the blender with your hands while it is running!
• Before you start the blender check the following:
• Remove all tools from the unit;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the
metering or mixing area;
• If your blender has been inoperative or unattended, check all settings before starting
the unit.
• At the beginning of your shift and after 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 is not only unsafe, but will void the warranty
on your equipment.
• When changing control settings to perform a different mode of operation, be sure
selector switches are correctly positioned. Locking selector switches should only be
adjusted by authorized personnel and the keys removed after setting.
• Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual blender action
• leakage
• improper maintenance
• NEVER stand or sit where you could slip or stumble into the blender while working
on it.
• DO NOT wear loose clothing or jewelry, which can be caught while working on an
blender. In addition, cover or tie back long hair.
Gravimetric Batch Blenders w/AB Control
Chapter 1: Safety
11
• 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.
Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.
When you need to perform maintenance or repair work on a blender above floor level, use a
solid platform or a hydraulic elevator. If there is a permanently installed catwalk around your
blender, use it. The work platform should have secure footing and a place for tools and parts.
DO NOT climb on unit, machines, or work from ladders.
If you need to repair a large component, use appropriate handling equipment. Before you use
handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)
be sure the load does not exceed the capacity of the handling equipment or cause it to become
unstable.
Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using
them to lift a load.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.
Do not restore power to the blender until all persons are clear of the area. DO NOT start and
run the unit until you are sure all parts are functioning correctly.
BEFORE you turn the blender over to the operator for production, verify all enclosure
panels, guards and safety devices are in place and functioning properly.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
Gravimetric Batch Blenders w/Mitsubishi ControlChapter 1: Safety
12
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. Make sure you know the model and serial number
of your equipment before contacting the manufacturer for parts or service.
Blending systems are as varied as the applications they service. All slide gate and auger
blenders are sized to meet the specific requirements stated by the Customer at the time of
purchase.
2-2
General Description
All blenders are designed to blend plastic pellets and regrind, and supply the blended material
to the processing machine. Standard equipment is not designed to blend powder or any other
materials.
Accessories
The manufacturer offers a variety of standard options for blenders including floor stands,
RAM feeders, loading equipment, etc. All accessories are designed and manufactured to
ensure proper results for your application.
Customer Service
The intent of this manual is to familiarize the operator and maintenance personnel with these
blenders and help your organization get the maximum service from your equipment. If you
have any questions regarding installation, service, repair, custom equipment, or applications,
please do not hesitate to contact us for the information required. Prices for additional
equipment, accessories, or repair parts will be furnished promptly upon request.
Note:
If you desire to use a blender for an application other than that for
which it was purchased, please contact your sales representative or our
factory to verify compatibility of the equipment with the new process.
Misapplication of the equipment could result in injury to the operator
or damage to the equipment.
Gravimetric Batch Blenders w/AB Control
Chapter 2: Functional Description
13
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® and “HC” mixer designs promote homogeneity
• Precision auger metering (standard on Auger Blenders, optional on Slide Gate
Blenders)
• Removable stainless steel mixer agitator and mixer wrap (Opti-Mixer® only)
Both Blender Styles
• Precision 1/10% span accurate cantilever load cell weighing system
• Safety-interlocked system shuts off compressed air and electricity if mixer is opened
• Compressed air hose with nozzle for clean-out
Figure 2: Slide Gate Blender (Shown on Left), Auger Blender (Shown on Right)
Gravimetric Batch Blenders w/AB Control
Chapter 2: Functional Description
14
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. Ingredients are metered as a
percentage of the overall batch.
• Parts mode recipe entry (i.e. 500:1) Ingredients are metered as a ratio
to each other within the batch
• Full control diagnostics
• Serial printer and RS-485 communications ports
Figure 3: Blender Controller shown with Mitsubishi Touch Screen
Gravimetric Batch Blenders w/AB Control
Chapter 2: Functional Description
15
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. The Slide Gate &
Auger blending system is made up of the following components:
• Material Supply Hoppers
• Slide Gate Metering Assemblies
• Auger Metering Assemblies
• Weigh Hopper
• Weigh Hopper Dump Valve
• Mix Chamber
• Operator Control Panel
Material Supply Hoppers
The material supply hoppers are located on top of the blender frame. These hoppers store a
supply of material for the individual metering devices. They are sized based on the total
throughput of the blender.
The blending system does not include any level indication devices on the unit. Optional lowlevel sensors are available. The blender controller will alarm if it runs out of material while
trying to make a batch, but low-level sensors will alert floor personnel to the problem sooner.
Each hopper is equipped with a sight glass and/or access door.
Figure 4: Typical Material Supply Hoppers
HINGED POLYCARBONATE
ACCESS DOOR
DOOR LATCH
PNEUMATIC SAFETY SWITCH
(IF EQUIPPED- OLDER
MODELS ONLY)
SIGHT GLASS (IF EQUIPPED)
DRAIN PORT WITH PLUG
Gravimetric Batch Blenders w/AB Control
Chapter 2: Functional Description
16
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. This
device decreases the stroke of the gate and reduces the metering orifice of the valve. The
unique diamond gate provides a square opening at any stroke length, providing more
consistent flow from smaller valve openings than conventional slide gates. This stroke
limiter may be necessary to accurately meter low percentage ingredients.
The air cylinders operating the slide gate are rugged, stainless steel cylinders designed for
industrial use.
Note: The unique diamond gate provides a constant aspect
opening that remains square regardless of the stroke
length of the cylinder. This design provides a wider cross
sectional opening when approaching a closed position,
and provides better flow of plastic pellets out of the
opening.
DIAMOND GATE OPEN
DIAMOND GATE 1/2 CLOSED
DIAMOND GATE 3/4 CLOSED
DIAMOND GATE CLOSED
WARNING!
Slide gates create a pinch-point hazard.
WARNING!
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning any blender, including all Slide Gate/Auger
models. Failure to do so may result in serious injury.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description
17
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.
Note:
If the blender is in metering mode with one of the slide gates open, do not open
the front door of the blender!
Note:
The safety switch shuts off the air supply to the blender. An open feeder slide
gate stays open, and an overflow of the weigh hopper can occur!
Auger Metering Assemblies
Auger blenders are equipped with auger metering units, including the following components:
• Cast aluminum feeder bodies
• Cast aluminum motor mounts
• Heavy-duty AC gear motors (Optional DC drives are available)
• Drain spouts with slide gate shut-off
• Machined steel auger
• Cast aluminum auger housing
• Spun aluminum material supply hoppers
• Cover with cut-out for vacuum receivers
Figure 5: Auger Blenders available with a Choice of Mixers
Standard “HC” mixer
Multiple regrinds and
more difficult materials
Gravimetric Batch Blenders w/Mitsubishi Control
Optional Opti-Mixer®
Pellets and one
free-flowing regrind
Chapter 2: Functional Description
18
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.
On a Slide Gate blender, the weigh hopper rests on each side on a precision cantilever load
cell. To remove the weigh hopper, lift the hopper from the bottom, hold the discharge valve
closed, and slide it out once clear of the locating tab on the bracket above the load cell.
Once the hopper has been cleaned, reposition it onto the load cell brackets, using care not to
damage the load cells. Position the hopper as close to the center position between the load
cells as possible.
Note:
Use care when replacing the weigh hopper, since the load cells are
delicate weighing instruments and can be easily damaged. Do not use
force to push in the weigh hopper. If it is positioned properly, it will
slide in very easily.
Note:
Load cells, if damaged, will have to be sent back to the manufacturer
for testing and evaluation.
Figure 6: Typical Weigh Hopper
LOCATING TABS
LOAD CELL
WEIGH HOPPER
LOAD CELL
AIR CYLINDER
DISCHARGE VALVE
The Auger-HC style weigh hopper is bolted in place, and is generally not removed except for
maintenance.
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19
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. When the weigh hopper discharge cylinder solenoid valve is not
electrically energized, it will provide air pressure to the air cylinder and hold the shaft in an
extended position, holding the dump valve closed.
When the air cylinder is actuated, the air pressure to the dump valve will be removed, causing
it to open.
The air cylinder on the weigh hopper includes a spring return to allow the cylinder to retract
in the absence of air pressure on the cylinder. This will cause the dump valve to open.
Caution!
The pneumatic system used on the Slide Gate/Auger blender, like all
pneumatic systems, is highly sensitive to oily, dirty, wet or contaminated
air. If oil, dirt, water, or any other air-borne contaminates enter the system,
the components could be damaged and injury to the operator could result.
A proper air supply must be supplied to the blender.
When the safety circuit is disabled, the air pressure to the cylinder will drop off by shutting
off all the air supply to the valve stack with the pilot operated master air valve. This will also
cause the weigh hopper discharge door to open.
Mix Chamber
All of the batch blenders are equipped with an integral mix chamber. The mix chamber holds
multiple batches of material so any variations in a batch are averaged over time.
Opti-Mixer™
The Opti-mixer™ is designed to provide bi-directional mixing action and can be easily taken
apart for cleaning. This design is standard on all Slide Gate blenders, and is optional on all
Auger models.
“HC” Mixer
The “HC” Mixer features an open wheel design and is best used for multiple regrind
materials and rigid pellets. It is standard on all Auger models.
WARNING!
Never reach into the mix section of the blender without disconnecting the power or air
supply.
WARNING!
Serious injury can result from getting your hand caught in the rotating mixer!
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Chapter 2: Functional Description
20
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. After installation and setup, simply enter in the
recipe and start the blender. See figures 7, 8 and 9 for controller pushbutton & touchscreen
tags along with typical setup and operator screens.
If it is desired to have a local display and control of the blender closer to a remote operator
station, an optional RS485 remote control panel (RCP) is available.
Figure 7: Controller Pushbutton & Touchscreen Tags
Button
(Power On)
(Power Off)
Function
Turns power on to the blender controller.
(Found on the back of the controller.)
Turns power off to the blender controller.
(Found on the back of the controller.)
Stops blender & restarts controller.
Press to move back one screen level in
controller function.
Move forward one screen level in controller
function.
Start (or stop) blender with current program
parameters.
Can erase current settings for one recipe or all
recipes.
Stops blender operation after current
inventory shutdown (if used) is completed
(This screen will be displayed.)
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21
Figure 8: Typical Setup Screens
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Chapter 2: Functional Description
22
Figure 9: Typical Operator Screens
LOGO
Slide Gate/Auger Blender
Version: Main 1.1
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description
23
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. Allows material to be metered into a vacuum conveying system.
CL-25 Pneumatic Loader for Additives. Compressed air loader to load low percentage
additives into the blender.
Remote Touch Screen
Note: The Remote Touch Screen option provides a second operator control.
This section describes the optional Remote Touch Screen. It is useful in situations when the
access to the control panel is difficult or limited. This remote control panel may be located up
to 50 cable feet away from the blender control panel. (Note: a signal amplifier may be
required for long distances. Consult factory with actual application.)
The remote interface provides the operator with all the functions of the standard Slide
Gate/Auger blender control panel. The keypad and display are identical to the blender panel.
Every Slide Gate/Auger blender panel includes a remote interface connection, and simply
plugs into the appropriate connector. The remote touch screen is an option and is not included
with the standard blender.
Pneumatic Slide Gate Below Mixer
The Slide Gate/Auger blending system can be equipped with an optional pneumatic slide gate
below the mixing chamber. The gate is used in applications when the blender is mounted
above a large hopper, or for gaylord filling, etc. This gate holds the material in the mixing
section, to ensure that it is properly mixed. Control of the mixer function is described below,
and is determined by the position of the “knife gate switch” located on the side of the back
control panel.
Figure 10: Mixer Slide Gate Switch Positions
Position
AUTO
OPEN
CLOSE
Description
Slide gate functions are automatically controlled by the blender
controller
Slide gate open all the time
Slide gate closed all the time
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Chapter 2: Functional Description
24
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. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working
environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
•
Identify and locate specific safety devices.
•
Understand the proper use of the safety devices provided.
•
Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial 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 of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the Slide
Gate/Auger Blender; however, it is the responsibility of the personnel operating and
maintaining the equipment to familiarize themselves with the safety procedures and the
proper use of any safety devices.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description
25
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. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on the Slide Gate/Auger Blenders are primarily concerned with pneumatic and electrical
power disconnection and the disabling of moving parts that may need to be accessed during
the normal operation of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these blenders are equipped with a line cord
plug (Shown in figures 11 and 12). This allows the operator or maintenance personnel to
unplug the unit from its power source and tag it out. The plug can then be tagged with any
number of approved electrical lockout tags available at most electrical supply stores.
Figure 12: Electrical Disconnect Plug
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Chapter 2: Functional Description
26
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.
Figure 13: Twist Cap Plug
Unscrew and remove plug
from motor
Motor
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 alter or tamper with this switch in any way.
Figure 14: Electrical Safety Interlock Switch (Located on mixer door)
Interlock Switch
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning the Slide Gate/Auger Blender. Failure to do so
may result in serious injury. No one but the person who installed the lockout may
remove it.
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27
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. Lower blender slowly.
Figure 15: Blender Lifting Lugs (1 on each side)
Caution!
Lifting Lug
3-2
Rigging and Placing the Unit
It is the intent of this section to familiarize the reader with the proper site requirements and
installation procedures of the Slide Gate/Auger blending system. The information in this
section is NOT meant to replace or supersede an established local or company implemented
procedures. It is meant to enhance them.
Site Requirements
This section describes site requirements in detail. These requirements are broken down into
mechanical mounting, electrical connections and pneumatic connections. Since the Slide
Gate/Auger Blender is available in several different mounting arrangements, it is necessary
for the reader to become familiar with the different arrangements.
Mounting Configuration
The Slide Gate/Auger System is available in (3) three basic mounting arrangements. They
are:
• Machine Mount
• Mezzanine Mount
• Floor Mount
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Chapter 3: Installation
28
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.
Verify that the machine throat is physically capable of supporting the Slide Gate/Auger
blending system 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. If there is a question as to the
mechanical stability of a mounting flange, contact the manufacturer’s
engineering department.
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 with the unit for actual height and width dimensions.
Note:
Allow at least 36” clearance around blender to provide adequate room for
cleaning, servicing, etc.
Using proper lifting equipment, lift the blender, using the lifting lugs attached to the top plate
of the blender. These lifting lugs can also be used to fasten horizontal or angled braces to the
blender if more stability is needed.
Take care to insure proper orientation with adequate access to operator controls, mix
chamber, and metering units.
Note:
Never weld on the blender, support stand, machine or mezzanine without first
removing the control panel and verifying that the blender is properly grounded.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 3: Installation
29
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. If there is a question as to the
mechanical stability of a mounting flange, contact the manufacturer’s
mechanical engineering department.
Ensure that the gravity feed tube is installed in a vertical position, so that the materials will
gravity flow to the extruder hopper. Use aluminum tubing or smooth wall flex hose.
Figure 16: Mezzanine Mounted Batch Blender
GRAVIMETRIC BATCH BLENDER
MEZZANINE (SUPPLIED BY
CUSTOMER)
EXTRUSION CONTROL WITH
RE-LOAD VALVE
(PURCHASED SEPARATELY)
If possible, use rigid tubing. Some flex hose will tend to sag and generate static that could
cause de-mixing between the blender and the extruder.
Make sure that adequate space is around the blender (36” recommended) to allow proper
cleaning, servicing, etc.
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Chapter 3: Installation
30
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.
Note:
The blender must be securely fastened to the floor before operating.
Note:
Manufacturer assumes no responsibility for any damages resulting from
improper installation or improper handling during installation.
Make sure that the blender is securely mounted to the floor before installing loading
equipment, loading with material and starting.
Make sure that the blender location is adequately away from high traffic aisles, and that fork
trucks, etc. cannot damage the blender. Ensure that normal day-to-day operations will not
place the blending system at risk of damage.
Figure 17: Typical Central Blender Layout
Blender
Pneumatic Slide Gate Below Mixer
Surge Bin
Take-off Compartment
Floor Stand
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31
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. Carefully adjust the load cell
brackets to ensure that the weigh hopper is centered on the brackets without rocking.
If for some reason the locating tabs do not align with the weigh hopper, they can
easily be loosened and adjusted.
Note:
Use extreme care when tightening bolts on top of the load cells so you do not
spring the load cells. The load cells are extremely delicate and should be
treated with care!
6. Check the slide gate metering assemblies to ensure they are not damaged, and will
slide back and forth freely. These are the most important items on the blender,
besides the load cell and weigh hopper assemblies.
3-3
Electrical Installation
The standard Slide Gate/Auger blending system is designed to operate on 120/1/60 supply
voltage (220/1/50 CE models are also available). The current requirements vary with the
blender’s size and throughput rating. For exact current requirements, check the blender serial
number tag, located on the rear plate of the mixer section.
If a step down transformer was provided, it should never be used to power anything other
than the blender. Loading equipment, etc. must be powered by another power source. As well
as possibly overloading the transformer, the additional equipment may induce power line
noise that may affect the operation of the blending system.
The transformer will be mounted and wired by the customer or your installer. If company or
local codes require fusing or disconnects, these items must be supplied, wired, and mounted
by the customer.
Note:
Each blending system MUST be connected to a separate source of power. Do
not connect other electrical equipment, especially self-contained hopper
loaders, on the same line as the blending system.
Ensure that the power entrance location on the blender panel remains unchanged. Make sure
that the proper size wire and proper wire routing techniques are used when installing the
supply wiring to the control panel. Care must be taken to ensure that the supply wiring does
not interfere with the low voltage DC wiring.
The blender is equipped with a plug that functions as the disconnect device (See Figure 11 on
Page 25 for an example). The mating receptacle must be installed no higher than 5’ feet
(1.6 m) above the floor. Make sure your installation conforms to your regional electrical
standards.
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Chapter 3: Installation
32
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.
Note:
As this blender uses air for blender metering functions, it is very important to
supply clean, dry air to the blender. Dirty or oily air can affect blender
accuracy, result in poor performance and cause injury. Provide a 5-micron air
filter on the air supply to the blender, and be sure excess oil is removed.
Figure 18: Customer-Supplied Components
DRY 60 psi COMPRESSED AIR
5 MICRON
FILTER
LUBRICATOR
CUSTOMER-SUPPLIED COMPRESSED AIR COMPONENTS
PRES SURE
REGULATOR
BLENDER
OS/OA BLENDER
The manufacturer provides all pneumatic lines on the blender piped to a single ¼” NPT
standard pipe thread fitting. The Slide Gate/Auger blending system requires approximately 1
cfm (1.7 m³/hr) @ 60 psi (4.14 bar) maximum air pressure for proper operation.
The working pressure of the blender cylinders is not to exceed 60 psi (4.14 bar). This is
adjustable by the regulator supplied on the rear panel of the blender. It is important to prevent
fluctuation in the air pressure to the blender by not installing the unit on an airline. If this is
the case, an accumulator tank with a check valve may have to be provided by the customer to
ensure the blender a steady air supply.
Caution!
To prevent damage to the equipment, do not exceed 60 psi (4.14 bar) air
pressure.
Caution!
Always disconnect the compressed air supply when working on any part of
the blender.
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33
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.
Generally, the stroke limiter (Item 30) is not required on major ingredients (usually number 1
and 3) and should be removed. If they are left in place, throughput of the blender will be
reduced.
To install the stroke limiter, drop it into the double slot on top of the gate assembly and
secure it in place with the socket head screw that is provided. Be sure to use the lock washer
to prevent the stroke limiter from coming loose.
Figure 19: Stroke Limiter
Weigh Hopper Installation (Slide Gate Models only)
Remove the weigh hopper from the shipping box and install it in the blender on the load cell
brackets. Connect the airline and close the mixer door, securing the latch.
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Chapter 3: Installation
34
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”). A feeler
thickness gauge, with the weigh hopper empty, should be used to set this.
If a feeler gauge is not available, the weigh hopper should be filled with the material that is to
be blended, and the stop adjusted so there is just a very small gap (a couple of sheets of
notebook paper) between the load cell, and the blender base stop. This will allow the load cell
to operate without mechanical restrictions and provide an overload safety. To adjust the stop,
adjust the screw located on the bottom of the load cell. Adjust the screw up to increase the
gap and down to decrease the gap.
Note:
THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE
FROM FRICTION, WITH NO MECHANICAL OBSTRUCTIONS OTHER
THAN THE LOAD CELL ITSELF.
Figure 20: Load Cell Mechanical Stop Adjustment
LOAD CELL
.040" GAP
STOP ADJUSTMENT
BOLT
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35
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.
Note:
Again, make sure that proper air supply connections are made to the blender,
as dirty, contaminated, wet air can damage blender components and can
quickly cause poor performance and accuracy!
Note:
Make sure that the blender is supplied with clean, dry,
60 psi (4.14 bar) compressed air.
3. After powering up the blender the following screen will be shown:
Note:
It may take 45-50 seconds for the screen to appear.
LOGO
Slide Gate/Auger Blender
Version: Main 1.1
This screen displays the software version of both the PLC and the PanelView. The Controller
will stay on this screen for about 10 seconds or you can touch the picture of the blender to
quickly skip to the Recipe Screen (Next Screen in sequence). The software versions are also
available on the Panel View Configuration Screen.
4. The screen shown below allows the operator to control the blender. The blender can
be started or stopped, the recipe values can be changed, and the actual vs. target data
can be viewed. Other data shown on this screen consists of the mixer status, recipe
status, and feeder type data. The Recipe Screen should startup in the Quickset recipe
mode. If so, enter a valid recipe.
Recipe Entry Mode
New Recipe
Input
Mixer Status
Feeder Type
Indicator
Start/Stop
Blender
Go To Inventory
Screen
Immediately
Stop Blender
Accept New Recipe
Gravimetric Batch Blenders w/Mitsubishi Control
Go To Recipe
Book
Chapter 3: Installation
36
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. These parameters are operator changeable; however, these items should only
require setup during the initial installation. Only authorized personnel should change them.
For security reasons, the menu that is used to access these parameters is password protected.
Many of the variables and setup parameters have been preset at the factory and do not need to
be changed. However, this section of the manual will address all of the blender setup
parameters that were available at the time of printing. The purpose of this is to familiarize the
reader with all the setup parameters and their usage.
A complete listing of all default values is provided at the end of this manual.
Recipe Entry Formats
Note: Refer to the menu structure on Page 59 for more information.
The Slide Gate/Auger System contains several operator friendly recipe menus. This section of
the manual lists these recipe menus:
• Recipe Page (Start/Setup)
• 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 Setup screen and is used to select one of
three available formats: “Quickset” Mode, Percentage Mode or Parts Mode. (“Quickset”
mode is the default setting preset at the factory.) In addition, every feeder in the blending
system does not need to have values entered (Percentage or Parts recipe formats), or a
material type (REGRIND, NATURAL, or ADDITIVE) in “Quickset” Mode recipe format.
Recipe Format Menu:
• “Quickset” Recipe, Percentage or Parts
• Metering Order
• Batch Size
• Inventory Shutdown
• “Batch ready” mode
• “Auto start” mode
• Weigh every batch options
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37
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.). The following Recipe
Modes are described on the next page:
“Quickset” Mode (Most common in injection molding)
The “Quickset” menu structure allows recipes to be entered and adjusted by touching the
buttons on the panel face (for 1 to 6 components). In this mode, hopper #1 is configured as
virgin, hopper #3 is configured as regrind, and the others are configured as additives, i.e.
color. The operator enters in the percentage of regrind and additives, and the virgin
percentage is automatically calculated. The regrind percentage represents a percentage of the
total batch, and the additives are based on a percentage of the virgin weight. This is useful
because the percentage of regrind can be changed without affecting the ratio of color or
additive to the virgin weight. Each percentage can be up to 100%, but not greater. The virgin
percentage is automatically calculated by the blender and the operator is not required to enter
it.
The ingredient names selected will be displayed on the run mode display so the operator will
know what material is being blended.
Note:
The #1 hopper (“NAT” - Virgin Material) recipe ingredient will not be shown
on the recipe setup menu.
Note:
ADD (Additive) designations will weigh the ingredient as a percentage of
natural material only.
Note:
RGD (Regrind) designations will weigh the ingredient as a percentage of the
total batch. (It is assumed the regrind has been generated from pre-blended
production and already contains the same color and/or additives.)
Note:
Virgin material must be loaded into hopper #1 and regrind into hopper #3.
Note:
Component #3 is designed to handle regrind and most models come equipped
with a larger, square gate to reduce the likelihood of bridging. If regrind is
being used, it should always be run through component #3. If you don’t have
regrind, another major ingredient can be run through component #3.
Please see Figure 21 on the next page for example calculations (setup).
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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) = 70.00%
Virgin + (5/100 x virgin) + (2/100 x virgin) + (1/100 x virgin) = 70/100
100 virgin + 5 virgin + 2 virgin + 1 virgin = 70
108 virgin = 70
Virgin = 70/108 = 64.81%
Virgin = 64.81% of batch
Additive1 = 5% of 64.81% = 3.24% of batch (5% of virgin)
Regrind = 30% of batch
Additive2 = 2% of 64.81% = 1.30% of batch (2% of virgin)
Additive3 = 1% of 64.81% = 0.65% of batch (1% of virgin)
Virgin + Additive 1 + Additive 2 + Additive 3 + Regrind = 100%
64.81% + 3.24% + 1.30% + 0.65% + 30.00% = 100%
“Percentage” Mode (Most common in extrusion and blow molding)
Extrusion processing often requires recipes in percentage format, especially if regrind is not
involved, i.e. blown or cast film.
In this mode, operators enter in values for each hopper up to 100%. The total of all the
hoppers must equal 100%. If they don’t, an error message appears on the Recipe screen and
prevents the recipe from being accepted. All hoppers are a percentage of the total batch size.
Note:
All ingredients are weighed as a percentage of the total batch.
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“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. For instance: Hop 1=300 parts, Hop 2=100 parts, Hop 3=10 parts, Hop 4=5
parts. This would mean that if the batch was divided into 415 parts, then Hop 1 would make
up 300 of those parts, Hop 2 would make up 100, Hop 3 10 parts, and Hop 4 5 parts.
The preset part will be divided by the total of all parts, with each part representing the
calculated weight for ratio control.
Figure 22: Example of a 5-component Blend in “Parts” Mode
Feeder Tag
Virgin
Regrind
Color
Additive
Total:
Preset Part
#1
#2
#3
#4
7,200
2,000
500
300
10,000
Calculated Weight
(Ratio Control)
7,200/10,000
2,000/10,000
500/10,000
300/10,000
Current Recipe Menu
Throughout the menu structure, the top left corner of the display will list the name of the
current screen that you are in. Each individual button will indicate instructions for
keystrokes. In the Recipe Format menu shown on the previous page, pressing on the mode
button displayed at the top of the screen will show the Current Recipe menu.
Note:
The blender will always run the percentages shown in the Current Recipe
menu display.
Switching Modes
Recipe Modes can be switched while the blender is making a batch. At any time the operator
can switch the recipe entry mode without affecting the current batch being made. The recipe
mode is part of the “New Recipe” and is separate from the running recipe.
Once in the Recipe format has been chosen, the following areas will need to be configured:
Feeder Metering Order:
The Slide Gate/Auger blender allows the operator to set the ingredient metering order when
making a batch. In order to access the metering order menu, enter the Setup menu and press
the “Recipe Format” button (refer to the menu structure on page 59). Once in the “Recipe
Format” menu, view “Metering Order.” This display will indicate the current order in which
the ingredients are metered. A Metering Order of “123456” means that the blender will feed
hopper 1 first and hopper 6 last.
In order to change the metering order, simply press the “Metering Order” button. In the next
screen, the operator must select a value from 1 to 654321 and press the enter (“ ”) key.
Once the desired metering order is displayed, simply press the “Done” key to save the
information and exit from the menu back to the Setup Menu. If the order is changed, then
you will need to touch “Accept New Recipe” on the Recipe Screen before the change
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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. This batch size is determined by the
blender’s weigh hopper size, the current recipe, and the bulk density of the ingredients.
Because the blending systems must handle a wide variety of materials, with varying bulk
densities, the actual amount of weight of material the weigh hopper will hold can vary
dramatically from application to application.
This feature allows the operator to change the size of the batch to be made. A value will need
to be entered between 0.5 to 99.9. This can also be changed while making a batch without
affecting the current running batch. If the size is changed then you will need to touch
“Accept New Recipe” on the Recipe screen before the change takes place. This feature
allows stored recipes with different batch sizes to easily be loaded without the operator
having to reconfigure the blender every time they want to load a stored recipe.
The weigh hopper size selected should be one that approaches the maximum capacity of the
load cells without over-filling the weigh hopper. During the initial setup of each blender, the
weigh hopper size setting should be checked to ensure that the weigh hopper is not overfilling
due to a large percentage of light weight regrind, etc. The batch size will vary from model to
model. The bulk density of the material being blended will also affect the batch size.
Note:
If running a high percentage of lighter density regrind, set the batch size so
that the mixer does not overfill, preventing the weigh hopper from fully
dumping when operating in “Batch Ready Mode”.
Figure 23: Typical Batch Size (Slide Gate Blenders)
Blender
Batch Size
(in lbs.)
Auger
SGA-012
SGA-030
SGA-060
7.0
20.0
35.0
Slidegate
SGB-450
SGB-900
SGB-2500
SGB-4000
SGB-5000
3.5
7.0
25.0
35.0
35.0
Inventory Shutdown
In many applications, the user of the Slide Gate/Auger System produces large runs of blended
material on the same recipe during production. An example may be a 40,000-lb. run of a
certain specification plastic extrusion. Others may wish to fill a 1,000-lb. gaylord box in a
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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. An example of
this screen is shown below:
Touch if you don’t
want to make another
batch
Touch to make
another box of
material
To enable this feature, simply enter a desired shutdown weight value (from 1 to 999999999)
into the Inventory Shutdown display line of the Recipe Format screen, under the Setup menu.
This feature can be configured while the blender is making a batch. If the Inventory
Shutdown is changed, then you will need to touch “Accept New Recipe” on the Recipe
screen before the change can take place. This allows stored recipes with different Inventory
Shutdown settings to easily be loaded without the operator having to reconfigure the blender
every time they want to load a stored recipe.
To disable this feature, simply enter a zero (0) value.
Batch Ready Mode:
This enables the blender to have a batch already made in the weigh hopper while the mixer is
full. Enabling this feature dramatically increases the maximum achievable blender rate.
AutoStart Feature:
By enabling this feature, the blender accurately finishes a batch that was interrupted by loss
of blender power. This option starts the blender if it was running prior to power loss. It does
not turn on the blender if it was previously stopped prior to power loss.
Weigh Every Batch:
This setting allows the operator to only weigh selected batches. The operator can choose
from the following: “Weigh Every Batch”, “Weigh Every Other Batch”, Weigh Every Third
Batch”, “Weigh Every Fourth Batch”, or “Weigh Every Fifth Batch.” If a batch is timed
instead of weighed then all components run concurrently instead of one at a time. This
dramatically increases the maximum blender rate, but introduces error into the timed batches.
Because the ingredients are not weighed, error is introduced into the Inventory Totals. Each
timed batch is assumed to be “perfect” and these “perfect” dispensed amounts are added to
the Inventory Totals.
Weigh Every Batch
This mode of operation weighs every component of every batch that is metered by the Slide
Gate/Auger blending system.
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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.
Running in every other batch mode normally does not affect the accuracy of the blender to
any great degree on consistent bulk density materials.
Every Third Batch
In the every third batch mode, the Slide Gate/Auger blending system will weigh each
component of the very first batch. The second and third batches will be metered using time.
The augers/gates are timed while weighing the first batch. The second and third batch will
use the time measured on the first batch. This sequence will continue as long as the blender is
running in this mode.
This allows for greater throughput of the blender, as the blender is running all the metering
devices simultaneously. Accuracy in this mode is not as good as weighing every batch, but
will be satisfactory in most applications.
Every Fourth Batch
In the every fourth batch mode, the Slide Gate/Auger blending system will weigh each
component of the very first batch. The second, third and fourth batches will be metered using
time. The augers / gates are timed while weighing the first batch. The second, third and fourth
batch will use the time measured on the first batch. This sequence will continue as long as the
blender is running in this mode.
This allows for greater throughput of the blender, as the blender is running all the metering
devices simultaneously. Accuracy is not as good as weighing every batch but will be
satisfactory in most applications.
Note:
This feature sacrifices blender weighing accuracy for blender maximum rate
and is only recommended under special circumstances.
1. Press the “Done” key two (2) times until you return to the “Recipe” page.
2. When you are in the “Recipe” screen, touch the hopper (1-6) that you want to change.
3. Touch the button that states: “Touch Here to Change.”
4. Enter in the new value (0-999.99) and hit the enter button (arrow)
5. Touch “Done” to return to the “Recipe” screen.
6. After you have entered the values for all of the hoppers, then hit “Accept New
Recipe” and the recipe will be entered.
Note:
The blender monitors the operator’s entries and determines if the recipe is
valid before accepting 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.
Note:
Recipes can also be changed while the blender is running. The new accepted
recipe is entered at the beginning of the next batch. This allows the operator to
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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. This menu is displayed in the “Report Setup” area of the Setup
screen. The printer menu is accessed by pressing “Report Setup” from the Setup menu.
Blender Number
Information will be
printed for.
Enable or Disable the
Auto Print & Auto
Clear Inventory
Report Interval in
hours (1-24)
Report Start Hour (0 to
23, 0 is midnight)
Go to back
Recipe Page
The printer is used to obtain batch ticket and inventory information. A batch ticket contains
the time and date, the actual blend percentages and the accumulated inventory numbers for all
networked blenders (1 to 999).
The blender can be configured to automatically print and clear inventory on a selected
interval. To automatically print or clear reports perform the following:
1. Enter in the Report Interval in hours (1-24).
2. Enter in the Report Start Hour (0-23, 0 is midnight).
3. Enable “Auto Print Inventory” and “Auto Clear Inventory.”
The user can select to only print the inventory on an interval if so desired by not enabling the
“Auto Clear Inventory” feature. The user should also enter in the blender number which will
identify the blender that the printout came from.
The printed inventory might not match the percentage shown, as the percentage shown is the
actual blender percentage running the current recipe. The inventory, depending on when it
was manually cleared, may or may not reflect the current recipe inventory. Some customers
like to run an accumulated inventory on ingredients coming from silos, etc., even though
several different recipes have been run on the blender. Others like to clear the inventory every
time the recipe is changed. The blender gives the operator the choice of either method.
The Report Setup Printer Menu contains four (4) options:
• Batch Interval
• Print Inventory
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• 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. The operator will have
to toggle between the “Recipe Format” and the “Report Setup” screens to configure the
settings properly.
If you want to print out on a time format, press the button next to the “Auto Print/Clear
Interval” key. The screen will then prompt the operator to set the time interval in hours (1 to
24).
If you want to change the hours between printouts, press the “Auto Print/Clear Interval” key
again to change the value to the desired time.
The operator will then need to program in when they want to begin the timed printouts.
Simply select the time (0-23, {midnight =0} on a 24-hour clock) and press the “Done” key to
retain the current settings in the “Report Setup” screen.
Batch Printout
If you wish to print out the inventory information on a batch interval basis, then simply enter
in the desired batch interval under the Recipe Format screen and the printouts will occur each
time that the number of batches programmed is produced. To set the batch interval, press the
bottom button “Weigh Every Batch”, “Weigh Every Other Batch,” etc. to change this setting,
keep pressing this button until the desired option is reached. Once you have chosen the
number of batches that will be produced between printouts, press the “Done” key to return to
the Setup screen. If the “Auto Print Inventory” feature has been enabled in the “Report
Setup” screen, then the printer will produce printouts according to the settings instructed
above.
Print Inventory
The print inventory menu item is used to produce on demand, inventory printouts. Before
selecting this item, be sure that the printer is properly connected and ready. This function will
generate an inventory printout with the current date and time information.
Display Time and Date
The display Time and Date item in the upper right corner of the “Report Setup” menu is used
to verify the current time and date information.
Blender Calibration
Note: It is not necessary to calibrate the weight scale on a brand new blender,
although it is recommended that the calibration be checked periodically to
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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. Verify that the calibration weights are not touching anything other than the load cell
bracket.
5. Enter the number stamped on the calibration weight. Follow the on-screen
instructions by touching “OK” and then follow the prompts.
6. The blender will evaluate the calibration and indicate if it is properly calibrated.
7. Press “Done” key three (3) times and you will return to the main menu.
Standard Calibration on a blender with an HC style mixer (Recommended only if
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. Empty the hopper and press “OK”.
4. Place the test weight on the hopper and press “OK”.
5. The controller will communicate whether the calibration was successful.
Verifying Calibration (Recommended on a periodic basis to ensure accuracy)
1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413”, then press
the “Enter” key.
2. Touch “Calibration” and then “Direct Scale Readout”.
3. Remove the weigh hopper.
4. Locate the weight display for each of the two load cells (or one load cell in the case
of an Auger blender with an “HC” style mixer), directly below “Current Bits.” Write
down the displayed value.
5. Add the calibration weight to each load cell mounting bracket and write down the
value displayed in “weight”, as in step 4.
6. Subtract the values recorded in step 4 from step 5. This is the measured weight. If
the measured weight is within a 0.003 pounds of the weight stamped on the
calibration weight, then you are within spec. If not, follow the steps above to
calibrate the blender. (If your blender is frequently out of calibration, verify the
operator is being cautious removing the weigh hopper for clean out.)
7. Press “Done” until you have reached the Recipe screen.
***Anything in the Diagnostics Menu that is not covered here is in the Detailed
Controller Setup Section***
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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. Since load cells
are reading the actual material weight that is metered by the feeders, the proper calibration
of these load cells is essential for the correct operation of the blender. This calibration
must be performed upon initial installation and startup of the blender. They should also be
checked once a month with a calibration weight and if necessary recalibrated to ensure
that they have not been damaged in the normal routine of removing and replacing the
weigh hopper for cleaning, color changes, etc.
The calibration of each load cell is accomplished by using two reference points on the output
of the load cell scale. The first of these points is known as the “Tare Weight”. This is the
weight of the empty hopper assembly on the load cell. This is also known as the zero weight
point (starting point) of the scale. This zero or starting point must be initialized with an empty
weigh hopper. There must be no binding or leverage put on the load cell.
The second weight point used in the load cell calibration procedure is a known amount of
weight for the weigh hopper. A calibration weight is provided with all Slide Gate/Auger
blending systems. The calibration weight is stamped with its actual weight on top. If this is
not available, any object with a known weight accurate to the nearest 1/100th of a pound, in
the 2 - 10 lb. range, proportional to your size blender, will suffice. (The weight should be as
close as possible to the maximum batch size you plan to run.) The weight will be in pounds,
unless the blender is provided for metric operation. In the case of a metric blender display,
the weight to be used is calibrated in kilograms.
Given the two weight points on the load cell scale, the controller should determine any other
weight on the load cell span. This is limited to the maximum capacity of the load cell. The
standard load cell used on these blenders has a span accuracy of 1/10%.
The maximum capacity of each load cell is clearly marked on top of the load cell. This value
will be indicated in kilograms (1 kg = 2.2 lbs.).
Weigh Hopper (Load Cell) Calibration on blenders equipped with an OptiMix mixer
Enter the Setup menu as described previously. See Page 59 for menu tree.
The factory pre-calibrates the weigh hopper on the Slide Gate/Auger blenders.
Button #3 on the Setup Menu is “Calibration”. Press it to enter the screen (shown below)
which will prompt you to enter the Calibration area. Press the button marked “Scale
Calibration” to enter the scale calibration menu.
Go Back to Setup
Directory
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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. Finally, the controller will ask you to replace the weigh hopper in the blender and
press OK to complete the calibration.
7. The controller will verify that the calibration was done correctly by showing
“Calibration Successful.”
Enter in the Calibration
Weight
Current Loadcell
Bits
Press here to perform
the calibration
Follow
Instructions
Go Back to the
Calibration Directory
Weigh Hopper (Load Cell) Calibration on blenders equipped with an HC style mixer
Enter the Setup menu as described previously. See Page 59 for menu tree.
The factory pre-calibrates the weigh hopper on the Slide Gate/Auger blenders.
Button #3 on the Setup Menu is “Calibration”. Press it to enter the scale calibration menu.
1. Once in “Scale Calibration, enter in the scale calibration weight value stamped on the
side of the weight.
2. Clean out the weigh hopper and press OK.
3. Place the calibration weight on top of the weigh hopper and press OK.
4. Remove the calibration weight when prompted.
5. The controller will verify that the calibration was done correctly by displaying
“Calibration Successful.”
Note:
It is imperative at this time that there is no mechanical binding of any kind on
the weigh hopper. Adjust the load cell stops as described on page 35 .
Feeder Calibration (Auger Blenders)
Feeder calibration should be done on all Auger blenders prior to start-up. This allows the
blender to configure the parameters which will best suit the auger size and gearbox ratio of
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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 blender does not see enough weight gain during the calibration process or if the weigh
hopper reaches maximum weight, then an error is given and the calibration is a failure.
Another useful feature on the “Feeder Calibration” screen is the ability to manually enter in
the “weight per second” values. This increases the blender learning process and the values
can be recorded for future blending.
Mix Timer
The mix timer is the amount of time that the mix motor will mix the material after it has
entered the mixing section of the Slide Gate/Auger blender. The timer has a range of 1 to 999
seconds.
To set the value of the mix timer, the user must gain access to the Setup Menu. After entering
the Setup menu, the user must select “Mixer and Dump Setup.”
Go Back to Setup
Directory
Selecting “Mixing Time” from the “Mixer and Dump Setup” menu will allow the operator to
view the current time setting for the mix timer and to adjust it as needed.
The mix timer is set to a default time of 10 seconds. This time can be adjusted up or down
depending on the amount of mixing needed for the materials being blended.
It is recommended that the mix time be held to the minimum, as segregation can occur from
over-mixing if the material bulk density and pellet configuration varies with materials in the
particular blend being processed.
Re-Mix Timer
In some applications, the Slide Gate/Auger blender will require the use of the re-mix timer.
Some materials tend to separate if they are mixed too long. This is possible when a
processing machine is running at a rate significantly below the capacity of the blender.
With external vibration, the heavier pellets will tend to flow to the bottom of the mix chamber
before the lighter material. This will occur even though the mixer is in a static mode. By remixing occasionally, this situation will be prevented.
The re-mix timer will start another mixing cycle if the blender has been idling long enough
for the re-mix timer to time out. The re-mix timer may be set on the “Mixer and Dump Setup”
screen from 1 to 999 seconds. Setting the re-mix timer to zero will disable this function.
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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.
Weigh Hopper Dump Time
The weigh hopper dump time is the amount of time the weigh hopper’s dump valve remains
open to allow weighed material to exit the hopper and enter the mixer.
To view and change the current weigh hopper dump time settings, enter the Setup menu and
select the “Mixer and Dump Setup” screen. Press the field next to “Dump Time” to set the
operation of the Dump Valve.
The dump timer on the dump valve has a default time of eight (8) seconds. This time can be
adjusted to optimize the blender cycle time.
The timer should be set to close the dump valve shortly after the material has totally dumped
from the weigh hopper. This time can vary due to material flow characteristics, and the size
of the batch that is programmed into the blender control. Experimentation with this setting
can allow the operator to determine the best cycle for the material being weighed.
Weigh Hopper Dump Delay Time
The dump delay time is the amount of time from the end of metering the last ingredient until
the start of the actual dump cycle. The start of the dump cycle is marked by the opening of
the weigh hopper dump valve. This value has a range from 1 second to 999 seconds. To view
and change the current dump delay time, enter the Setup Menu, select “Mixer 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.
Weigh Hopper Dump Cycle
The dump cycle allows the weigh hopper dump valve to cycle, or open and close, a number
of times prior to commencing with the next batch cycle. The setting allows from 1 to 9 dump
cycles between batches (open and closed cycles).
The normal and default factory setting is 1, meaning the weigh hopper dump valve will open
at the end of the weighed batch and close after the batch is discharged into the mixer.
Setting the dump cycle to more than one cycle may be useful when blending high static, dusty
material or those that have sticky tendencies. This will cycle the dump valve open and closed
to allow any material that may cling to the dump valve.
To enter the dump cycle menu, first enter the Setup menu by pressing the Manufacturer’s
icon from the main menu. Enter the password and press enter. Next, press the button marked
“Mixer and Dump Setup”. The display will show the “Mixer and Dump Setup” menu. Press
the “Dump Cycle” key to enter a dump cycle value and press enter. Please refer to the menu
structure tree shown on page 59.
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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.
Continuous Mixing Option
This mode of operation turns the mixer on after initial startup and will continue to run
continuously, unless the remix time is set to jog the mixer during high level mixer operation.
This option is used for sticky materials that tend to bridge and block off the mixer discharge
to the processing machine.
Setting Date & Time
The Set Date & Time feature is located in the “Panel View Config” menu of the Setup
Screen. This feature allows the operator to set the Slide Gate/Auger Blender’s internal time
clock and date. The clock data must be entered in the traditional Hours, Minutes, and
seconds. The date must be entered in Years, Months, and Days. All values in this screen can
be entered by pressing on the related button and choosing the correct number.
Press to
Access the
Panel View
Go back to
Setup Directory
Feeder Alarm Setup & Flags
This screen allows the operator to configure the alarm settings for each individual feeder. It
can 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 the alarm flag is set to “Stop”, the blender will
not continue. It stops on that component continuing to try and meter. The optional low level
proximity switches have their own separate alarm. The alarm will sound, but does not stop
the blender. To configure each hopper do the following:
1. Enter the Setup Menu.
2. Once in the Setup menu, press “Alarm Setup.” This will take you to the “Alarm
Flags & Feeder Setup” screen.
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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.” Once the settings for these features have been set on the
displayed feeder, select a new feeder to configure as desired.
6. Press the “Done” key at the bottom to exit this screen.
An alarm message will be shown if any alarm condition occurs. A message will pop up on
the screen until the alarm condition is resolved. The operator can press “OK” on this pop-up
to hide the screen temporarily, but if the alarm condition is still unresolved, then the message
will reappear after a short delay. During an alarm condition, not only will a visual alarm
show up on the screen but also an audible alarm will sound. The audible alarm will sound for
10 seconds and reappear every 30 seconds until the cause of the alarm is resolved. The
following is a list of all alarm names and descriptions:
• Hopper 1-6 Out of Material: This alarm indicates that a hopper is out of material and
signals the operator that they should check the resin system.
• Max Hopper Weight Exceeded, check batch size: This alarm indicates that the
weight in the weigh hopper has exceeded the maximum allowed weight. This alarm
can happen if the operator changes material density and does not perform a feeder
calibration, but will usually be automatically fixed after the first batch. As long as this
alarm doesn’t continue to reappear, then the operator should not be concerned. If the
alarm continues to occur, then the operator should have maintenance check the
blender.
MAX HOPPER WEIGHT
EXCEEDED
check batch size
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• 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. If this does not correct the problem, then the scale calibration should be
checked by maintenance.
CALIBRATION ERROR
Clean out hopper
and check
• Power Interruption while metering a Batch: This alarm indicates that the blender’s
power was turned off while the blender was making a batch. The batch accuracy is not
affected as long as the blender is configured for “AutoStart.” The blender will finish
the last batch accurately even if the material was dumped into the mixer when the
power was turned off.
POWER INTERRUPTION
While metering a
Batch
• PLC Battery Low: PLC battery is low and may cause the blender to lose both the
program and the blender configuration. Notify Maintenance immediately.
PLC BATTERY LOW
• PLC Module Loaded: This alarm occurs after a software upgrade to the PLC. The
alarm instructs you to turn off power to the blender, remove the Memory Module, turn
on power, and then reconfigure the blender parameters.
PLC MODULE LOADED
• Blender Powered On/Off: These are only logged in the Alarm Log and does not
cause a pop-up message or audible alarm. Each time the blender is powered on or off,
the time and day is logged to the Alarm Log.
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• 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. The operator can not access any screens until
E-Stop is deactivated. The Panel View will then put the screen back to the display that
the operator was on prior to hitting the E-Stop.
Network Communications Baud Rate & I.D. Settings
The blender’s baud rate is the speed at which data is transferred to and from the blender’s
communication port. The blender IP is the address of this blender on a network. The Slide
Gate/Auger blender is factory set up at 192 baud, with an IP address of 01.
In order to change the values, enter the Setup menu, press the “Network Setup” button and
change the values accordingly. Baud rates available are 120, 240, 480, 960, 192. Blender
ID’s can range from 1 through 255.
Enable or Disable
the Ethernet
Module
Configurator
Change Blender’s IP
Address and Subnet
Mask
Go back to Setup
Directory
Additional settings that usually do not have to be changed:
1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413”, then press
the “Enter” key.
Note:
If the controller is set to Continuous Mixing, then the blender will run
continuously while the blender is operating. If it is set to “Timed Mixing” then
the mixer will run for the “Mixing Time” setting when a batch is dumped into
the mixer.
2. Touch the “Mixer and Dump Setup” key to enter the amount of 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.
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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. (Set the time so that all the material in the weigh
hopper has a chance to be evacuated.)
6. Press the number next to “sec” on the “Dump Delay” line for the optional dump
delay setting. This is the amount of time to start the mixer prior to dumping material
into the mixing chamber. Set to “0” to disable this feature.
7. Press the number next to “Dump Cycles” to enter the number of times that material
will be dumped from the weigh hopper. This allows the dump valve to open and shut
repeatedly when the weigh hopper is empty to shake lose any sticking material. If
this feature is set to “1” then the batch will dump normally.
8. Press the number next to “sec” on the “Mixer Dump Time” to enter the amount of
time that the mixer will run while dumping material out of the knife gate below the
mixer. This feature assists in cleaning out the mixer.
9. Press “Done” to return to the “Setup” screen.
10. Press “Alarm Setup” on the “Setup” screen to look at the “Alarm Flags & Feeder
Setup screen.”
11. This screen allows you to change the way alarms on each feeder function. Enter the
feeder you wish to configure by pressing the corresponding feeder number under
“Select Feeder”. You can select “Stop if “Out of Material” which means if there is
any kind of alarm on this feeder, the blender process will stop (i.e. The feeder supply
hopper is out of material.) You can also set it to “Continue if “Out of Material.”
This mode will alarm but let the blender continue to operate or you can set it to “No
Alarm on Out of Material” mode. “No Alarm” mode does not set off any alarms. In
addition, an “Out of Material Alarm Silence Delay” specifies the amount of time
before an alarm will be set off.
12. Press “Done” to return to the “Setup” screen.
3-6
Initial Startup
The operator can startup the blender by selecting the button that says, “Push to Start or Stop”
(startup) on the left side of the Recipe Screen, depending on whether the blender is currently
running or is stopped. Simply touch the button to either start or stop the blender. If the
operator selects “Stop Blender” then the current batch in progress is first finished and then the
blender will stop making new batches.
3-7
Shutting Down Blender
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.
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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). Pressing the highlighted box
next to the feeder number, the operator can enter a valid recipe or use a previously stored
recipe from the recipe book.
1. The blender is started by turning system on or material dropping below level switch
in mix chamber.
2. Metering gates are opened (or auger motors are turned on) to meter material into the
weigh hopper in the programmed order.
3. Each component is weighed, then the batch is dumped into the mix chamber
(provided the mixer “High level” switch is not covered).
4. The material is mixed in the mix chamber and flows into the processing machine.
5. The optional slide gate below the mixer may control the flow of material to the
molding machine or extruder.
Quick Start Procedure
New Recipes
1. Calibrate the weigh hopper before running the blender (This will improve inventory
accuracy.). See page 45 for calibration instructions.
2. Ensure that all ingredient supply hoppers to be used are filled with material. Virgin
material should be loaded into hopper #1 and regrind into hopper #3.
Note:
Hopper #3 is equipped with an oversized square gate to assist in the feeding of
the regrind material.
3. Enter the recipe menu on the LCD panel by turning on the PanelView controller (It
will automatically default to this screen), and enter the blend recipe desired following
the steps listed below:
• Touch the box (labeled 1-6) that shows the hopper you want to change.
• Touch the “Touch Here to CHANGE” button.
• Enter in the new value (0 to 999.99) and hit the enter button (arrow).
• Touch “Done”.
• After you have entered the new values for all hoppers (1-6), then push
the “Accept New Recipe” button and the recipe will be entered.
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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.
Recipes can also be changed while the blender is running. The new accepted recipe
is entered at the beginning of the next batch. This allows the operator to modify the
new recipe without affecting the blender until they hit the “Accept New Recipe”
button.
Existing Recipes
1. The operator can load a previously stored recipe from the Recipe Book. The Recipe
book also allows the operators to save the current running recipe. This can be done
by performing the following steps:
• Touch the Recipe Book icon located on the Recipe Screen.
• Select a stored recipe by changing the number next to “Recipe #”
• Touch “Load” and then “Done” (This will take you back to the Recipe
Screen.).
• Touch “Accept New Recipe” to accept the loaded recipe into the
blender.
To Save a running recipe to the Recipe Book:
• Go to the Recipe Book by touching the Recipe Book icon located on
the Recipe Page.
• Select a stored recipe by changing the number next to “Recipe #”.
• Touch “Save Running Recipe” and then “Done”.
2. Press “Push to Start or Stop” button to start blender.
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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. This display, which is defaulted to when the
controller is turned on, provides the operator with the following information and options:
• The ability to change Recipe Values
• Accept a newly entered Recipe
• Start or Stop the blender
• Access to the Recipe Book
• Access to the Clean-out Screen
• Access to the Inventory Screen
• Access to the Controller Setup Screen
Note:
Please refer to the Slide Gate/Auger menu structure shown on the next page.
The menu tree shows the structure for a standard Slide Gate/Auger blender.
When the unit is initially installed the Manual Control menu will be used. This screen is
primarily used for trouble shooting the blender. All outputs can be controlled manually and
all digital inputs from the proximity switches can be viewed. Pressing the “Manual Control”
key when in the “Setup” menu accesses this screen. To gain access to the “Setup” menu, a
password will be requested.
Warning Message
Open or Close
Feeder
Empty Entire
Blender
Test Alarm
Output
Open or Close
Weigh Hopper
Current Hopper
Weight
Start or Stop
Mixer Motor
Go back to
Setup Directory
Open or Close
Mixer Knife
Gate
Low Level
Prox Status
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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
Erase all stored recipes
Modify the product ID for a
stored recipe
Return to the “Recipe” page
Recipe Format
¾
¾
¾
¾
Percentage, Parts, or Quick
Set
Batch Size
Inventory Shutdown
“Batch ready” mode
“Auto start” mode
¾
¾
¾
¾
Blender Number
“Auto clear” option
“Auto interval” setup
Auto start time
¾
¾
¾
Scale Calibration
Direct Scale Readout
Feeder Calibration
¾
Report Setup
“Clean Out” Page
¾
¾
¾
¾
Empty the blender hopper(s)
Manually Operate the mixer,
weigh hopper dump gate, and
the slide gate below the mixer
View and test all inputs and
outputs on the blender
Return to the “Recipe” Page
“Inventory” Page
¾
¾
¾
¾
¾
View the accumulated
inventories
View batch time
View blender’s maximum
capacity
View the average process
rate
Return to the “Recipe” Page
Calibration
Mixer and Dump Setup
¾
¾
¾
¾
¾
¾
¾
Mixing Time
Remix Time
Dump Time
Dump Delay
Dump Cycles
Mixer Dump Time
Timed/Continuous Mixing
Option
¾
View software version
¾
Access F940 “Config” setup to
modify time settings
F940 “Config”
Units
Blender data units (lbs. or
kgs.)
¾ Target vs. actual data units
(lbs. or kgs.)
¾
“Setup” Page
¾
Login from the inventory page
by hitting “Login” and entering
in your password. Then
access setup by touching the
Sterling Logo.
Alarm Log
¾ View and clear the alarm log
Alarm Setup
¾ “Stop/Continue” when out of
material
¾ “Alarm/No Alarm” when out of
material
¾ “Alarm Silence” delay
User Interface Lock
¾ Lock the user interface to
prevent others from making
changes or viewing your
blender. Be sure to logout
after locking.
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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.
Topics covered in this section are:
• General Operation
• Recipe Menu
• Optional Printer Menu
All personnel operating the Slide Gate/Auger blending system should read this section of the
manual before operating the blending system.
Recipe Book (Storage) Menus
In many applications, it is favorable to hold several recipes in the memory of the blending
system. The Slide Gate/Auger blender has provided for this by incorporating the
manufacturer’s recipe book software.
The recipe book is capable of holding 50 different recipes. These may be stored and recalled
by number. During this section of the manual, the operator may wish to revert to the Menu
Tree Diagram on page 59 of this manual.
It is important to note that the recipe book only stores and recalls recipes. The blender will
operate on the current recipe only, so a recipe must be recalled from the book to the current
recipe for it to be active.
Each recipe stored in the recipe book may be displayed and/or modified. Only the current
recipe will be blended.
Always verify that the Current Recipe is showing what you 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 Recipe
• Erase One Recipe or the Entire Recipe Book
Erase One
Stored Recipe
Select a Stored
Recipe
Erase Entire
Book
Stored Recipe
Details
Load Stored
Recipe
Go to Recipe
Page
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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. We suggest keeping a looseleaf notebook with 50 tabbed pages as a reference to what is kept in the blender so this can be
the standard for all blenders in the plant, etc. To save a running recipe to the Recipe Book
perform the following steps:
1. Enter the Recipe Book by touching the Recipe Book icon located on the Recipe
Screen.
2. Select a stored recipe by changing the number next to “Recipe #.”
3. Touch “Save Running Recipe” and then “Done”.
Load a Saved Recipe from the Book
The load from book function allows the operator to retrieve a previously stored recipe from
the 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 before installing a new recipe in its
place. To load a previously stored recipe from the Recipe Book:
1. Enter the Recipe Book by touching the Recipe Book icon located on the Recipe
Screen.
2. Select a stored recipe by changing the number next to “Recipe #.”
3. Touch “Load” and then “Done” (this takes you back to the Recipe Screen).
4. Touch “Accept New Recipe” to accept the loaded recipe into the blender.
Note:
If replacing the current recipe with one that is downloaded from the
Recipe Book, make sure that the previous recipe has been saved, as it
will be overwritten by the new downloaded recipe.
Display Recipe Contents
The display recipe function is used to verify the contents of a recipe number before it is
loaded from the recipe book. In order to view the desired recipe, the operator must enter the
number which contains the recipe he wishes to view. Once a valid recipe number is entered,
the display will indicate the contents of the stored recipe in percentages.
Erase Recipe or Entire Book
The Erase Recipe or Entire Book function is used to eliminate old or outdated recipes from
the recipe book. If the operator only wants to delete one recipe, the configuration for that
recipe should be currently displayed on the screen. The controller will only prompt the
operator if they want to erase the entire book when that key is pressed. Once a recipe number
is deleted, the contents of that recipe are lost. The recipe number may be used again in the
future for new recipes.
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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.
Open or Close
Feeder
Test Alarm
Output
Warning Message
Open or Close
Weigh Hopper
Current Hopper
Weight
Start or Stop Mixer
Motor
Open or Close
Mixer Knife Gate
Empty Entire
Blender
Go back to Setup
Directory
Low Level Prox
Status
The dump valve opens as soon as the “Press to Open Feeder” key is pressed. This easy feeder
clean out option also serves as a means for emptying a batch that is held in the weigh hopper
if the “Press to Open Weigh Hopper” key is pressed when the blender is stopped. To
open/close feeder numbers 2, 3, 4, 5 & 6 press the number next to “Press to Open Feeder” to
select the feeder you desire to empty and the “Press to Close Feeder” key to close the dump
valve. Touch the “Done” key to return to the recipe menu. After entering a recipe, the
operator will restart the blending system, putting it back in normal operation.
Note:
Before starting Slide Gate/Auger blending systems, each ingredient hopper in
the current recipe must contain material! Virgin material must be loaded in
hopper #1 and hopper #3 should only be used for regrind!!
Once the operator initiates the run mode of operation, the blending system controller will
begin monitoring the mixer high-level switch. Nothing will happen until the mixer high-level
switch is uncovered. This tells the controller that the mixing chamber is capable of holding
another batch of material.
Once the mixer high-level switch is uncovered, and the weigh hopper has dumped, the system
will meter the ingredients from the supply hoppers, through the metering units, into the weigh
hopper. Each component will be metered individually to allow accurate weighing of the
material.
Each component is metered in the order specified by the “Metering Order” setup. See the
Installation & Setup chapter for further details.
Once the final ingredient specified in the recipe has been metered into the weigh hopper, the
controller will take a final weight reading of the weigh hopper. This will start the “Dump
Delay” timer. (See Page 50). Once the dump delay timer has timed out, the controller will
activate the weigh hopper dump valve, initiating the weigh hopper dump cycle.
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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.)
The level sensor is located on the back wall of the mixer chamber. If the sensor is covered
with material, the indicator light on the back of the sensor will be lit.
Once this sensor is uncovered, the indicator lamp on the back of the level sensor will go out.
This level sensor must be uncovered for approximately 1 - 2 seconds to indicate to the
controller that there is room in the mixing section to accept a batch of material.
When the controller has determined that the mixer is ready for an additional batch of
material, the controller will begin metering material into the weigh hopper assembly.
Color Changes
The color change procedure is meant for use with the basic Slide Gate/Auger Blender. This
procedure assumes that the color component of the blend is in an additive ingredient hopper
(#2, #4, #5, or #6).
Note:
The blender must be stopped to make color changes. The processing machine
can operate on virgin material only during this procedure with an optional
quick color change bypass tube that can be installed to bypass the blender.
Contact the factory for details.
1. Disable and clean any color loading equipment. Please refer to the loading equipment
manual for any clean up recommendations.
2. Using the blender “Abort” or “Push to Start or Stop” key, put the blender in stop
mode. After the cycle has completed, switch “OFF” the main power switch and
unplug the blender power supply.
3. Open the upper mixer access door. This shuts off air to the blender circuit by
deactivating the master air valve. Then unplug the quick disconnect from the air
supply hose to the blender to further ensure that no air pressure is supplied to the
blender.
WARNING!
Always unplug the main power cord.
WARNING!
Always disconnect the air supply to the blender.
WARNING!
...prior to performing any operations inside any access areas of the blender where
there are moving parts.
4. Remove the weigh hopper by unplugging the air line disconnect fitting, holding the
dump valve closed, lifting the hopper to clear the load cell brackets, and gently
pulling the weigh hopper out of the blender.
Note:
To reduce the chance for damage to delicate load cells, use care when lifting
the weigh hopper off load cell locating tabs and when reinstalling the weigh
hopper on load cell brackets.
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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. Blend and Reclaim
normally provides a JIT (Just in time) approach to the minor ingredients, so that a
minimum amount of material is held in the blender so that color changes can be made
easily.
6. If any other ingredients need to be changed for the next recipe, simply drain the
larger hoppers with the drain tubes provided on the side of the hoppers. When the
material level is below the drain tube, open the slide gate manually to dump the rest
of the material. If you wish to speed the emptying process, material can be manually
drained out of the slide gate assembly into a dump chute or bucket, while draining
from the drain tube.
7. Using a vacuum cleaner or air hose, clean out all the hoppers that have been emptied.
Always start at the uppermost part of the blender and work downward to prevent dust
and pellets from falling into an already cleaned area.
Note:
The auger metering assemblies on Auger blenders can be removed after the
hoppers above them have been drained.
8. Clean the weigh hopper and mixer assemblies on the blender using a vacuum cleaner.
The mixer agitator is removable for cleaning if desired.
9. Reinstall any metering units that were removed from the blender during clean out.
10. Reinstall the weigh hopper using care to center the hopper on the load cells on the
weigh hopper bracket.
11. Load the blender with new material.
12. Restart the unit with the new recipe.
WARNING!
Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing or cleaning any product, including all Slide Gate/Auger
blending systems. Failure to do so may result in serious injury or death.
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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. The ingredient weights (Unit Values) are in
pounds, unless the metric display is selected.
Pressing the “NEXT” key when in the default recipe mode display will toggle to the next
screen, which is the Inventory Display. This can be done at any time, but if the blender is in a
critical mode such as dumping, and updating inventory, etc., it may ignore the keystroke.
Simply press the “NEXT” key again, the Inventory screen will be displayed.
Blender
Maximum Rate
Average Batch
Time
Inventory Totals
Clear the
inventory
totals
Go to Recipe
Page
Material
Usage Rate
Accumulated
Number of Batches
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 the amount of material that has been used for each feeder, this screen
is also a summary display that shows the total inventory, the time for the last batch, and the
average rate of the blender.
If the blender is run in “Percentage Mode” instead of “Quickset” Mode during operation, the
“Percentage Mode” will use the blender inventory numbers shown on the Inventory screen to
calculate the percentages for each ingredient. It is important to zero the inventories when a
recipe is changed to have this screen accurately reflect the current percentages of the recipe
in-process.
Note:
Blender inventories must be cleared when the current recipe is started to show
accurate percentages for the current recipe.
Note:
To clear inventories, press the “Clear Inventory” key on the “Inventory”
print screen.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 4: Operation
65
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. The blender will finish the current
batch of material to the specifications set in the Setup portion of this manual. 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. An example of
this screen is shown below:
Touch if you don’t
want to make another
batch
Touch to make
another box of
material
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 4: Operation
66
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.
System model #
Daily
Serial #
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Date/
By
Inspect blender for
any loose partstighten them
immediately.
Verify quality of
compressed air
supply.
Verify mixer door is
properly latched.
Every week
Inspect metering
gates for proper
operation.
Check to make
sure that all hose
connections are
air tight.
Every month
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Inspect air
regulator and air
safety circuits, if
equipped.
Recalibrate blender
only If necessary.
- Photocopy this page for your maintenance records -
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 5: Maintenance
67
Dec
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.
Corrective Maintenance
Electrical
This section is designed to give the operator an overview of the electrical system that controls
the Slide Gate/Auger blending system. Since the blender’s control panel is a self-contained
pluggable item, seldom will a maintenance person be required to enter the control panel. For
purposes of understanding the system, it is advisable that the maintenance personnel be
familiar with not only the internal workings of the control panel, but also with the input and
output signals to the Slide Gate/Auger blender.
This section includes the following:
• Internal components of the control panel
• Input signal to the control panel
• Output signals from the control panel
Internal Components of the Control Panel
Note: See Installation Packet supplied with unit for complete electrical schematics.
This section describes the internal components of the Slide Gate/Auger blending system
control panel. It is not the intent of this section to completely familiarize the reader with the
details on industrial control panel construction or standards, but simply to familiarize the
reader with the major components inside the control panel.
The customer must supply 120/1/50 or 60 (or 220/1/50 or 60) via wires L1 & L2 (N). Please
insure that the earth ground connection is properly connected to an established earth ground.
“Power on” is indicated by a lighted on/off switch.
“Slide gate below mixer” switch controls position of optional slide gate.
“Safety Active” light displays status of safety interlock circuit. Audible alarm horn alerts
operator to blender fault.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 5: Maintenance
68
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. This is known as the load cell’s excitation
voltage.
Output Signals from Programmable Controller
The Slide Gate/Auger blending system uses several output control signals to control the
process. All of these are very similar in nature, the first of which is the mixer motor control.
The mixer motor is controlled by a PLC output.
The weigh hopper dump valve output functions similar to the mix motor output. Please refer
back to the wiring diagram. The origin of the weigh hopper dump signal is a PLC output.
The auger motor outputs are driven from a control output from the PLC.
Each blending system includes an auxiliary customer alarm output. This dry contact can be
used to switch a remote alarm signal.
The customer alarm output is provided to actuate or energize a variety of alarm horns,
buzzers, strobe lights, and beacons. These are normally provided by the customer, and care
will have to be exercised not to exceed the maximum current draw (3 amp maximum). The
contacts will close whenever the control detects a fault that will somehow inhibit the blending
system from properly blending the material.
Note:
The customer alarm contact is open if the panel control power is turned off.
Note:
This contact is for use with a customer supplied alarm device as described
above.
Note:
The alarm contact has a maximum load of 3 amps.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 5: Maintenance
69
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. In this case, an oiler may be required on the blender to keep the air cylinder seals
lubricated.
Note:
As this blender uses air for blender metering functions, it is very important to
supply clean, dry air to the blender. Dirty air can affect blender accuracy,
result in poor performance and cause injury. Provide a 5-micron air filter on
the air supply to the blender and be sure excess oil is removed.
If a dirty air filter is noticed during regular inspection intervals, replace with a new 5-micron
air filter. Check the compressed air supply and ensure that the necessary steps have been
taken to remove any oil from the process.
DRY 60 psi COMPRESSED AIR
5 MICRON
FILTER
LUBRICATOR
CUSTOMER-SUPPLIED COMPRESSED AIR COMPONENTS
PRES SURE
REGULATOR
BLENDER
OS/OA BLENDER
The working pressure of the blender cylinders is 60 psi. This is adjustable by the regulator
supplied on the rear panel of the blender. (It is important that the air pressure to the blender is
not fluctuating by installing the unit on an air line with other equipment using large volumes
of air. If this is the case, an accumulator tank with a check valve may have to be provided by
the customer to ensure the blender a steady air supply.)
WARNING!
Always disconnect the compressed air supply when working on any part of
the blender.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 5: Maintenance
70
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. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
Problem
Corrective action
Check to make sure that air is hooked up and the regulator gauge
reads at precisely 60 PSI.
Nothing happens when I push
“Start Blender”
Check that the access door to the mixer is shut properly.
Look on the Recipe Screen. If you see “Mixer Full”, then check
the mixer. If the mixer is not full, then check that the mixer prox
is adjusted properly (small screw on back).
“E-STOP has been Activated”
is shown
Check the E-Stop located on the front of the blender panel.
“Interface has been Locked” is
shown
Click “Unlock” and enter in your User Password.
I’ve forgotten my User
Password
Contact the Service Department.
POWER INTERRUPTION
ALARM
Power was lost during a batch. Check your power source unless
you intentionally killed the power during the batch.
PLC Battery Low
Change out the PLC with your spare and reprogram new unit.
Send old PLC back to Mitsubishi for repair.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 6: Troubleshooting
71
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. In this mode, if a short power interruption occurs, the
blender will automatically restart.
Check the power supply. Make sure that it has +5 VDC output to
the CPU board. Adjust to +5 VDC, ±0.1 volt.
Check the display ribbon cable connection to the CPU board and
the display. See the electrical chapter for more information.
Check the contrast adjustment located on the display board.
Check keyboard ribbon cable connections.
Check the CPU board for “lockup”. To do so, reset the CPU board
by cycling the power off and on at the motor control panel.
Weigh hopper occasionally
overfills.
Check batch weight setting in the recipe menu. See the 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 supply hoppers to verify proper ventilation. If
a vacuum receiver has a leaking flapper valve and the supply
hopper is not vented, the blender computer can learn inaccurately
and cause an overfill condition on the next few cycles.
Check the load cell connections to the panel.
Material tends to separate in the
mixing chamber.
Check the mix timer setting. This problem is normally due to over
mixing. See the mix timer section in the setup chapter. Reduce the
time until the problem is corrected.
Check the mixer drive to ensure that the agitator is turning
properly.
Check the high level switch in the mixer to lower the level slightly.
Material sticks to the flapper of
the weigh hopper and is not
dumped.
Increase the Dump Cycles setting in Mixer and Dump Setup.
Too much material remains in
the mixer.
Increase the Mixer Dump Time in Mixer and Dump Setup.
The material is not being mixed
thoroughly.
Increase the Mixing Time in Mixer and Dump Setup. Actually if
you over mix material, you can have the same problem. If you
have the blender set for “Continuous Mixing” then change it to
“Timed Mixing” and adjust the Mixing Time appropriately.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 6: Troubleshooting
72
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.
Stop the Blender and the Start it again. This causes the blender to
perform an automatic feeder calibration. If this doesn’t fix it, then
manually perform feeder calibrations and retest.
Printer did not print
Check that the printer is a SERIAL printer. If not, then you will
need to either get a SERIAL printer or purchase a SERIAL to
PARALLEL converter.
Check printer communication settings under Panel View Config.
I’m missing an Automatic
Inventory Report
Check the blender’s Alarm Log to determine if the blender was
powered up during the print time. The blender keeps track of
Power On and Off conditions.
Check that the date and time are set correctly on the Panel View
Config Page.
Blender occasionally dumps an
incorrect batch.
The blender intermittently dumps a batch of material with one or
more of the components incomplete.
Check the recipe information; ensure that both the percentages and
batch size are set properly.
Check the status of the alarm flags & Feeder Setup to ensure that
all of the feeders are set to Retry. In addition, if the blender is
configured for timed batches then this can cause error.
Check supply hopper ventilation to prevent problem associated
with leaky vacuum receiver flappers.
Blender keeps dumping after
mixer is full.
Check the mixer high-level switch sensitivity. When the sensor is
covered by material, the indicator lamp on the back of the switch
should be lit. To adjust the sensitivity, use the small adjustment
screwdriver that was provided with the blender. The adjustment
pot is located on the back of the sensor. Rotate clockwise to
increase the sensitivity (less material in front of the switch to
actuate it). Rotate counter clockwise to decrease the sensitivity
(more material covering the switch).
Check the mixer high-level sensor connection to the control panel.
Blender will not batch with
empty mixer.
Check the mixer high-level switch sensitivity. Fines may have
coated the level switch; it needs readjustment.
Check the proximity switch connection.
Make sure that the recipe is correct.
Check batch size.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 6: Troubleshooting
73
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. If the unit has two (2) power inlets
with a separate power inlet for the mix motor the overload fuse
will be located in the rear junction box on the blender frame.
Check the power source to the blender.
Check the load cell in diagnostics under direct scale readout. Place
a calibration weight on the weigh hopper; determine if the weight
corresponds.
Check the load cells to make sure that a pellet has not jammed
under a load cell.
Check the load cell connections to the control panel
Check the power supply voltage and readjust as necessary as
described earlier.
Check the memory battery voltage on the CPU board. If the
battery is dead, the blender “forgets” settings when the power is
off. Replace it with a new battery. Order a spare CPU board; send
the replaced one back to the factory to have a new battery holder
and battery installed. If this is done in the field, the controller
warranty will be voided.
Out of Material Alarm is
displayed, but there is material
in the hopper.
Go to the Manual Control Page and check to see if “Hop Low”
equals “1”. If it does, then adjust the low-level prox until the value
reads “0”.
Ensure that the material hopper is properly vented. If the vacuum
receiver is leaky, then this will cause the problem. To test this, fill
up the hopper and turn the loader off to prevent leaking.
If this isn’t the problem, then increase the “Out of Material Retry
Limit” found under Feed Algorithm Options (see manual).
I’m not getting Out of Material
Alarms
Check the Alarm Flags & Feeder Setup to see if the feeder is
configured to give you an alarm.
Calibration Weight Exceeded
Clean out the hopper and retest. If this doesn’t fix the problem,
then perform a scale calibration. Also, check to sure that the
Dump Time is not set extremely low. If all else fails, check the
value set for the Max Empty Weight. This might need to be
increased.
The feeder calibration values
are moving too much.
First, check that the displayed actual dispensed weight is accurate.
If this is OK, then check to see if the hopper is properly vented.
To do this, fill hopper and turn off the loader and retest.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 6: Troubleshooting
74
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.
Do other feeders calibrate correctly? Is the feeder I’m trying to
calibrate a large gate? If these are true, then lower the Batch % for
Feeder Cal setting under Feed Calibration Options. This can be
observed by looking at the Hopper Weight display.
None of the feeders calibrate? Check the Scale Calibration. If this
is correct, then lower the Batch% for Feeder Cal setting under Feed
Calibration Options for each feeder. This can be observed by
looking at the Hopper Weight display.
Check the dump time setting. It may be set too short.
Weigh hopper does not empty
completely.
If this does not correct the problem, clean the weigh hopper and
recheck the scale diagnostics readout. If not showing (0) zero when
empty, re-calibrate the scale.
Verify application is not exceeding blender capacity.
Blender does not make rate.
Verify additive percentage is not higher than designed, resulting in
excessive dispense time.
Verify all materials are feeding freely through the metering gates
or augers.
I have changed the recipe entry
mode, metering order, batch
size, inventory shutdown,
weigh every batch mode, or
feeder type and alarm flags, but
the change hasn’t taken place.
All of these settings are part of the current running recipe. This
makes it easy for the operator to load a stored recipe without
having to reconfigure all of these parameters for the new recipe.
All you have to do is touch “Accept New Recipe” to load these
values into the running recipe.
A feeder always puts too much
material in the batch.
Check that the Gate Cycle Time is set correctly. If it is then lower
the Initial % of Target to Meter. These are found under Feed
Algorithm Options. Make small adjustments and retest.
Increase the Gate Cycle Time. This is found under Feed
Algorithm Options. Make small adjustments and retest.
A feeder is retrying more than
2-4 times.
Increase the Allowed Underfeed value under Feed Algorithm
Options.
Decrease the Retries before Double Gate Time.
Other service problems or questions can be answered by contacting the Service Department.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 6: Troubleshooting
75
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. THE FOREGOING EXPRESS WARRANTY
IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTEES,
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE
PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The
Company’s obligation is limited to repair or replace FOB the factory any parts that are
returned, prepaid, within one year of equipment shipment to the original purchaser, and
which in the Company’s opinion, are defective. Any replacement part assumes the unused
portion of this warranty.
Warranty Restrictions
This parts warranty does not cover any labor charges for replacement of parts, adjustment
repairs, or any other work. This warranty does not apply to any equipment which, in the
Company’s opinion, has been subjected to misuse, negligence, or operation in excess of
recommended limits, including freezing or which has been repaired or altered without the
Company’s express authorization. If the serial number has been defaced or removed from the
component, the warranty on that component is void. Defective parts become the property of
the warrantor and are to be returned immediately, without any further use or handling.
Warranty Liabilities
THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT
RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or
limitation of special, consequential or incidental damages, so the above limitation may not
apply to you. The Company’s obligation for parts not furnished as components of its
manufactured equipment is limited to the warranty of the manufacturers of said parts. The
company neither assumes nor authorizes any other persons to assume for it any liability in
connection with the sale of its equipment not expressed in this warranty. No person, agent,
manufacturer, distributor, dealer, installer or company is authorized to change, modify or
extend the terms of this warranty in any manner whatsoever.
The time within which an action must be commenced to enforce any obligation of the
Company’s arising under this warranty, or under any statute or law of the United States or
any state thereof, is hereby limited to the duration of this warranty. Some states do not permit
this limitation, so the above may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. For transactions
involving the potential applicability of international law or that of a foreign country,
this warranty policy and the procedures hereunder shall be governed by
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 7: Appendix
76
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.
No modifications are allowed to this equipment that could alter the CE compliance
Ambient temperature:
40 degrees Celsius – Maximum (104 degrees Fahrenheit)
Humidity range:
50% relative humidity
Altitude:
Sea level
Environment:
Clean, dust-free and non-explosive
Radiation:
None
Vibration:
Minimal, i.e. machine mounting
Special installation requirements: Clean, dry compressed air 1 cfm @ 60 psi (1.7
m³/hr @ 4.14 bar)
Allowable voltage fluctuation:
+/- 10%
Allowable frequency fluctuation: Continuous
+/- 1%
Intermittent
+/- 2%
The addition of an auger feeder (RAM option) for regrind will increase the electrical
supply requirements of a standard blender.
Nominal supply voltage:
120/1/60 or 220/1/50/60 (Verify on serial number tag)
Earth ground type:
TN (system has one point directly earthed through a
protective conductor)
Power supply should include a neutral power connection.
Over-current protection is supplied in the blender, but additional protection should be
supplied by the user.
The plug on the power cord serves as the electrical disconnect device.
Unit is not equipped with three-phase motors.
N/A
Blender is not equipped with local lighting.
Functional identification
Blender is equipped with a CE mark
Blender is supplied with an operating manual in the language of the destination country.
Cable support may be required for power cord, depending on final installation.
No one is required to be in the interior of the electrical enclosure during the normal
operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.
Doors can be opened with a screwdriver, but no keys are required.
Two-hand control is not required or provided.
All blenders should be moved around and set in a place with a lift truck or equivalent.
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix
77
28. There are no frequent repetitive cycles that require manual controlrepetitive
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.
Slide Gate Blender (-E) Series Specifications
Slide Gate Blender Specifications
450
Number of materials blended
900
4
Slide gate (adjustable, in (mm)) square
Supply hopper capacity, ft³ (l)
4000
5000
2 to 6
2 to 5
2 (50)
3 (76)
4 (101)
0.5 (14)
1.5 (42 )
2.5 (71)
Weigh hopper capacity ft³ (l)
0.12 (3.4)
0.25 (7)
1.1 (31)
Typical batch size, lbs. (kg)
3 (1.3)
8 (3.6)
35 (16)
Mixer capacity, lbs. (kg)
6 (2.7)
25 (11)
30
16
75 (34)
1/2 (.37)
22
2 kg ea.
5 kg ea.
20 kg ea.
1/6 (.12)
Mixer motor size, HP (kW)
Mixer speed, rpm
Load cell capacity (2 per blender)
Blended material discharge opening, in (mm)
Maximum blending rate (approx.), lbs/hr (kg/hr) ➀
3 (76)
4 (101)
450 (204 )
900 (408)
4000 (1820)
Weight of machine (approx.), lbs (kg)
145 (66)
200 (91)
600 (275)
5000 (2270)
Shipping weight (approx.), lbs (kg)
➀ Based on 78% virgin, 20% regrind and 2% Color.
200 (91)
400 (185)
850 (390)
Auger Blender (-E) Series Specifications
Auger Blender Specifications
Number of materials blended
002
012
030
2 to 4
060
2 to 6
Supply hopper capacity, ft³ (l)
0.25 (7)
1.0 (28)
Weigh hopper capacity, ft³ (l)
0.10 (3)
0.17 (5)
0.6 (16)
1.4 (40)
3 (1.3)
5 (2.3)
20 (9)
35 (16)
Typical batch size, lbs (kg)
Mixer type
2.5 (71)
Opti-mixer
Mixer capacity, lbs (kg)
“HC”
40 (18)
Mixer speed, rpm
6 (2.7)
1/6 (.12)
30
Load cell capacity (1 per blender except 002)
2 @ 2 kg
10 kg
Mixer motor size, HP (kW)
Blended material discharge opening
40 (18)
100 (45)
1/2 (.37)
1 (.746)
50
10 kg
20 kg
3 (76)
4 (101)
Maximum blending rate (approx.), lbs./hr. (kg/hr)
100 (45)
400 (181)
1500 (680)
Weight of machine (approx.), lbs (kg)
145 (7.0)
200 (91)
450 (205)
600 (275)
Shipping weight (approx.), lbs (kg)
200 (91)
400 (185)
650 (295)
850 (390)
Note:
3000 (1360)
Blender features and specifications are subject to change without notice.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 7: Appendix
78
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
3.0 Amp Fuse
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix
79
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.
53243
Description
Air Cylinder (weigh hopper dump)
20kg Load Cell
10197
Mixer Agitator (Opti-Mixer)
63881
Mixer High Level Sensor
53266
Slidegate Air Cylinder (5” stroke) – OS-070 only
53280
Slidegate Air Cylinder (6” stroke) – OS-100 only
0801100
A0565882
Calex Module
A0565881
(PLC back base)
A0565885
Touch Screen Interface
A0542200
1.5 Amp Fuse
A0565892
3.0 Amp Fuse
Auger Gravimetric Batch Blending Systems
Model 002 (with Opti-Mixer™)
Part No.
53292
Description
Air Cylinder (weigh hopper dump)
2kg Load Cell
10220
Mixer Agitator (Opti-Mixer)
63881
Mixer High Level Sensor
15286
Auger Shaft Seal
11147AM
1” Feed Auger
11146AM
¾” Feed Auger
11145AM
½” Feed Auger
51444
71 RPM Feeder Gear Motor
51486
95 RPM Feeder Gear Motor
53404
240 RPM Feeder Gear Motor
A0565882
Calex Module
A0565881
(PLC back base)
A0565885
Touch Screen Interface
A0542200
1.5 Amp Fuse
A0565892
3.0 Amp Fuse
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 7: Appendix
80
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
3.0 Amp Fuse
Model 012 with Rotary (HC) mixer
33126
dump cylinder
33138
dump valve
10 kg Load Cell
55347
safety switch assy
08841
mix agitator
55348
Mixer High Level Sensor
51253
mixer gear reducer
51353ME
1/2hp mix motor
61-3AB10
10-amp fuse
15370
dump cone
59643
25 amp relay
15286
mix motor shaft seal
15241
frame gasket
15239
wrap/door gasket
A0565882
Calex Module
A0565881
(PLC back base)
A0565885
Touch Screen Interface
A0542200
1.5 Amp Fuse
A0565892
3.0 Amp Fuse
Model 012 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
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 7: Appendix
81
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
3.0 Amp Fuse
Model 060 with Rotary (HC) Mixer
33126
dump cylinder
33138
dump valve
55347
safety switch assy
30kg Load Cell
55348
Mixer High Level Sensor
51415
mixer gear reducer
51354
1hp mix motor
61-3AB10
10-amp fuse
15209
dump cone
80151
power supply
59643 2
25 amp relay
61-DRIAC5
input module
61-DROAC5
output module
15286
mix motor shaft seal
A0565882
Calex Module
A0565881
(PLC back base)
A0565885
Touch Screen Interface
A0542200
1.5 Amp Fuse
A0565892
3.0 Amp Fuse
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 7: Appendix
82
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 Blenders w/Mitsubishi Control Chapter 7: Appendix
87
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 Blenders w/Mitsubishi Control Chapter 7: Appendix
89
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 4.14 bar (60 psi)
Mixer Speed 16RPM
Blender Mass 400 lbs/(180 KG)
Electrical Diagrams &
Pneumatic Diagram
Street Address
Telephone Number
7-6
City, State Zip Code
Technical Assistance
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
Call [630] 595-1060 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
Call [630] 595-1060 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or nonunion installations.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 7: Appendix
90
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. Unauthorized changes to these
factory settings by inexperienced operators may prevent the unit from
operating properly, and may void part or all of the warranty.
Programmable Settings
The Slide Gate/Auger blender software program has been designed to allow some
customizing to achieve certain desired operating parameters. The following is a listing of the
selections that are “field” programmable, followed by the procedure for doing so.
This menu is accessed by pressing the manufacturer’s icon when in the “Setup” Directory
Screen menu.
Touch this icon and
enter in the Service
Password to access the
Engineering Only
Directory
Enter the long password “3145348” and press “Enter”. The factory setup section displays the
“Engineering Only” screen. The screen similar to that shown below should be displayed and
use the keystrokes described herein to change or toggle the parameters.
Go back to
Setup
Directory
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 the gate or auger. This test meters for the calculated
time based off the target weight entered on this screen. The blender does not retry or adjust
the time of the meter to reach the target, but instead always meters for the same amount of
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 8: Addendum
91
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. If it does not, then either the weigh hopper is not balanced
correctly or the scale calibration is not correct. Refer to the Troubleshooting Section of this
manual for additional details.
Stop the Meter
Target Weight
Change Method
Meter Data
Go back to
Engineering
Only Directory
Advanced Weight Options Screen
This screen allows you to modify the weight filter, adjust the mechanical time to settle the
weigh hopper after dumping, adjust the mechanical time to settle after a feeder has introduced
material into the weigh hopper, adjust the Maximum Empty Weight of the hopper, and to
enable the batch weight data to be dumped to a printer every batch for diagnostic purposes.
The data that is dumped to a printer is the same data shown on the Recipe Screen. No
averaging is done with the data shown to the Customer. Targets vs. Actual are actually what
is in the batch without any “smoke and mirrors.”
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 should not be modified except by the developer except under unusual
circumstances.
Adjust the limit for
“Hopper Over Max
Weight”
Weight Filter
Weight/Sec.
Filter
Adjust Settle Time
Print weight data
every batch
Go back to
Engineering Only
Directory
Feed Algorithm Options Screen
This screen allows the user to configure how the blender metering algorithm works. The user
can adjust the Initial percentage of Target to Meter, the Allowed Underfeed value, the
number of retries before Double Gate Time, the allowed Weight/Sec Drop, and the Out of
Material retry limit.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 8: Addendum
92
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. An error is shown if the current feeder calibration feed time was too
short, the feed time was too long, or if the hopper weight exceeded 110% of the set batch
weight. In the case that the feeder exceeded 110% (maximum hopper weight) due to a high
rate hopper then the “Batch % for Feeder Cal” setting might be set too high. Consult the
manufacturer if this problem arises. The current feeder calibration values are also shown on
this page. It is not necessary to perform feeder calibrations. The blender will
automatically learn these values during the batch.
Go back to
Engineering Only
Directory.
Mechanical Options Screen
This screen allows the user to change the number of hoppers, the predetermined gate cycle
time, and the mixer bump time for detecting high level.
The gate cycle time has been measured and set at the factory, but might need to be adjusted if
we change the mechanical design of the gate, solenoids, and air cylinders. This setting will
vary depending on whether you are using a gate or an auger.
Go back to
Engineering
Only Directory
Gravimetric Batch Blenders w/Mitsubishi Control Chapter 8: Addendum
93
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.
Go back to
Engineering Only
Directory.
Customer Setup Menu
Units
This screen allows the user to change the blender’s unit of measurement. The entire blender
can be configured in either Kgs. or Lbs., while the Target vs. Actual data can be configured
for either regardless of the blender’s units.
Change
Blender’s
Units
Change Target vs.
Actual Units
Go back to
Setup
Directory
Network Setup
This screen allows the blender to be configured for use with the Ethernet Option. The
blender will automatically configure the Ethernet module’s IP Address and Subnet Mask if
the configurator is enabled. Whenever you modify the IP Address or subnet, you either need
to reboot the PLC or touch “Send Ethernet Config to Module.”
Change
Blender’s IP
Address and
Subnet Mask
Enable or
Disable the
Ethernet
Module
Configurator
Go back to
Setup
Directory
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 8: Addendum
94
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. No “Out of Material” alarm will
be given regardless of how the alarm is configured unless the user has purchased and wired in
the low level proximity switches in each hopper. To configure each hopper, perform the
following steps:
1. Select a feeder by touching the “Select Feeder” box.
2. The current settings for that hopper will be shown.
3. Make the necessary adjustments and select a new feeder to configure if desired.
4. Hit “Done” to exit.
Select a Feeder to
Configure
Enable or Disable
Retries
Enable or Disable
Alarms
Go back to Setup
Directory
Change the Alarm
Silence Delay
Alarm Log
This screen shows the last 100 stored alarms. The log can be viewed, printed and cleared.
Alarm Log
Clear Alarm
Log
Print Alarm
Log
Gravimetric Batch Blenders w/ Mitsubishi Control
Go back to
Setup
Directory
Scroll Through
Alarm Log
Chapter 8: Addendum
95
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.
Note:
Call the Service Department for assistance or for further explanation of these
or any other programmable features, which may or may not be shown in this
manual.
Note:
Information included in this manual is subject to change without notice.
Passwords
User Password
“5413”
Maintenance Password
“3145348”
Caution!
Maintenance password should only be supplied to qualified personnel!
The program can be compromised.
Gravimetric Batch Blenders w/Mitsubishi Control
Chapter 8: Addendum
96