ACS 882.00207.00 User Manual

Slide Gate/Auger Gravimetric Batch Blenders

With Mitsubishi Controller

Part Number: 882.00207.00

Bulletin Number: BF2-605

Effective: 10/26/05

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

_________________________ _________________________

_________________________ _________________________

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 [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

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 [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

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

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
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 [phone]; for all other countries, call
our international desk at [phone]. 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

to the return of any material, authorization must be given by the manufacturer. A

Prior
RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

returned material purchased from the manufacturer returned is subject to 15% ($75.00

ALL
minimum) restocking charge.

returns are to be shipped prepaid.

ALL

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

to the return of any material, authorization must be given by the manufacturer. A

Prior
RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

returns are to be shipped prepaid.

All

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
manufactured by our company, purchased components are covered under their specific
warranty terms.

the item is found to be defective in materials or workmanship, and it was

Gravimetric Batch Blenders w/Mitsubishi Control iii

Table of Contents

CHAPTER 1: CHAPTER 1: SAFETY ......................................... 7

1-1 How to Use This Manual ............................................................................................. 7

Safety Symbols Used in this Manual.....................................................................7

1-2 Warnings and Precautions .......................................................................................... 9

1-3 Responsibility ............................................................................................................ 10

General Responsibility.........................................................................................10

Operator Responsibility .......................................................................................11

Maintenance Responsibility................................................................................. 12

Reporting a Safety Defect ................................................................................... 12

CHAPTER 2: FUNCTIONAL DESCRIPTION............................ 13

2-1 Models Covered in This Manual................................................................................13

2-2 General Description................................................................................................... 13

Accessories .........................................................................................................13

Customer Service................................................................................................13

2-3 Typical Features & Components ............................................................................... 14

Mechanical Features ...........................................................................................14

Controller Features.............................................................................................. 15

Slide Gate & Auger Blender System Component Description.............................16

2-4 Options ...................................................................................................................... 24

Remote Touch Screen ........................................................................................24

Pneumatic Slide Gate Below Mixer .....................................................................24

2-5 Safety Devices and Interlocks ................................................................................... 25

CHAPTER 3: INSTALLATION ................................................... 28

3-1 Uncrating the Equipment...........................................................................................28

3-2 Rigging and Placing the Unit ..................................................................................... 28

Site Requirements...............................................................................................28

Mounting Configuration ....................................................................................... 28

Mechanical Installation ........................................................................................32

3-3 Electrical Installation.................................................................................................. 32

3-4 Pneumatic Installation ............................................................................................... 33

3-5 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

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

3-6 Initial Startup .............................................................................................................55

3-7 Shutting Down Blender.............................................................................................. 55

CHAPTER 4: OPERATION ........................................................ 56

4-1 Start-up...................................................................................................................... 56

General Operation...............................................................................................56

Quick Start Procedure .........................................................................................56

4-2 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

4-3 Shutting Down the Blender........................................................................................ 66

CHAPTER 5: MAINTENANCE ................................................... 67

5-1 Preventative Maintenance Schedule......................................................................... 67

5-2 Preventative Maintenance......................................................................................... 68

5-3 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

Slide Gate Gravimetric Batch Blending Systems ................................................79

Auger Gravimetric Batch Blending Systems........................................................80

7-5 Blender Identification (Serial Number) Tag ............................................................... 90

7-6 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/Mitsubishi Control Chapter 1: Safety 7

Gravimetric Batch Blender Safety Tags

Tag Description Tag Description

Pinch Point Slide Gate

Shear Point Rotating
Mixer

High Voltage Inside
Enclosure

PE

Read Operation &
Installation Manual

Earth Ground

Protected Earth Ground

Shear Hazard Rotating
Auger

Lifting Point

Gravimetric Batch Blenders w/Mitsubishi ControlChapter 1: Safety 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 Auger Blenders

• 450 • 002

• 900 • 012

• 2500 • 030

• 4000 • 060

• 5000

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/Mitsubishi 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

• Precision auger metering (standard on Auger Blenders, optional on Slide Gate

Blenders)

• Removable stainless steel mixer agitator and mixer wrap (Opti-Mixer

®

and “HC” mixer designs promote homogeneity

®

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/Mitsubishi 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/Mitsubishi 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
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

alarm if it runs out of material while

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/Mitsubishi 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

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.

1

/8” diameter free-flowing plastic pellets

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 Optional Opti-Mixer®

Multiple regrinds and Pellets and one

more difficult materials free-flowing regrind

Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 18

A

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

LOAD CELL

IR CYLINDER

The Auger-HC style weigh hopper is bolted in place, and is generally not removed except for
maintenance.

WEIGH HOPPER

DISCHARGE VALVE

LOCATING TABS

LOAD CELL

Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 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!

WARNING! Serious injury can result from getting your hand caught in the rotating mixer!

Never reach into the mix section of the blender without disconnecting the power or air

supply.

Gravimetric Batch Blenders w/Mitsubishi Control 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 Function

(Power On)

(Power Off)

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.)

Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 21

Figure 8: Typical Setup Screens

Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 22

Figure 9: Typical Operator Screens

Slide Gate/Auger Blender

LOGO

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
with the standard blender.

Pneumatic Slide Gate Below Mixer

The Slide Gate/Auger blending system can be equipped with an optional
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 Description

AUTO

OPEN Slide gate open all the time

CLOSE Slide gate closed all the time

Slide gate functions are automatically controlled by the blender
controller

included

pneumatic slide gate

Gravimetric Batch Blenders w/Mitsubishi Control 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

Gravimetric Batch Blenders w/Mitsubishi Control 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.

Gravimetric Batch Blenders w/Mitsubishi Control Chapter 2: Functional Description 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!

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

Lifting Lug

• Mezzanine Mount

• Floor Mount

Gravimetric Batch Blenders w/Mitsubishi Control 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