Melco 882.00273.00 User Manual

Gravimetric Slide Gate Batch Blender

Mitsubishi Controller

Part Number: 882.00273.00

Bulletin Number: BF1-615.3

Effective: 11/07/07

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 2007
All rights reserved.

Shipping Info

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 parts and service department
immediately 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.

BF1-615.3 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

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.
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
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

BF1-615.3 iii

Table of Contents

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.......................................................................................10

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 and Components ...........................................................................15

Mechanical Features...........................................................................................15

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

System Component Description..........................................................................16

Supply Hoppers ...................................................................................................16

Slide Gates...........................................................................................................17

Weigh Hopper......................................................................................................18

Mix Chamber.......................................................................................................20

Operator Control Panel Display...........................................................................20

2-4 Optional Components................................................................................................25

Pneumatic Slide Gate below Mixer......................................................................25

Low Level Sensors..............................................................................................25

Mezzanine and Floor Stands...............................................................................25

Regrind Auger Metering (R.A.M.) Hopper...........................................................26

Additive Feeder Hopper ......................................................................................26

Take-off Compartments.......................................................................................26

2-5 Safety Features.........................................................................................................27

Safety Circuit Standards......................................................................................27

Fail Safe Operation .............................................................................................27

Safety Device Lock-Outs.....................................................................................27

Twist Cap Plug Connected to Each Feeder Auger Motor....................................28

Electric Safety Interlock Switch ...........................................................................29

CHAPTER 3: INSTALLATION..................................................30

3-1 Uncrating the Equipment...........................................................................................30

3-2 Mechanical Installation..............................................................................................30

Site Requirements...............................................................................................31

Mounting Configurations .....................................................................................31

Machine Mount....................................................................................................31

Mezzanine Mount................................................................................................32

Floor Mount (Central Blender)............................................................................33

3-3 Electrical Connections...............................................................................................34

3-4 Pneumatic Connections ............................................................................................34

BF1-615.3 iv

Initial Set-up ..............................................................................................................35

3-5

Mechanical Set-up...............................................................................................35

Stroke Limiters for Metering Gates.....................................................................35

Weigh Hopper Installation...................................................................................36

Final Connections................................................................................................36

Controller Set-up .................................................................................................37

Blender Controller Menu Structure .....................................................................38

Blender Calibration ..............................................................................................39

Alarm Setup.........................................................................................................41

Network Setup .....................................................................................................42

Setting Date and Time .........................................................................................42

Additional Setup Parameters ...............................................................................43

3-6 Initial Startup .............................................................................................................44

CHAPTER 4: OPERATION.......................................................45

4-1 Start-up......................................................................................................................45

General Operation...............................................................................................45

Quick Start Procedure.........................................................................................45

New Recipes........................................................................................................45

Existing Recipes ..................................................................................................46

4-2 Operation Procedures...............................................................................................46

Operator Displays................................................................................................47

Recipe Entry Formats..........................................................................................48

“Quickset” Mode (Most common in injection molding).....................................50

“Percentage” Mode (Most common in extrusion and blow molding).................52

“Parts” Mode (Often used in Compounding Applications).................................52

Recipe Setup.......................................................................................................52

Mixer and Dump Setup........................................................................................54

Alarm Flags.........................................................................................................56

Feeder Clean Out................................................................................................59

Recipe Book........................................................................................................60

Color Changes ....................................................................................................62

4-3 Shut-down.................................................................................................................63

CHAPTER 5: MAINTENANCE .................................................64

5-1 Preventative Maintenance Schedule.........................................................................64

5-2 Preventative Maintenance.........................................................................................65

5-3 Corrective Maintenance ............................................................................................65

CHAPTER 6: TROUBLESHOOTING .......................................67

6-1 Introduction................................................................................................................67

CHAPTER 7: APPENDIX..........................................................72

7-1 Technical Specifications............................................................................................72

Equipment Specifications....................................................................................72

Annex B Information............................................................................................73

7-2 Drawings and Diagrams............................................................................................74

Final Assembly....................................................................................................74

Mixer Sub-Assembly ...........................................................................................75

Hopper Sub-assembly.........................................................................................77

Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional)..................78

BF1-615.3 v

Hopper Additive Feeder Sub-Assembly (Optional)..............................................79

Weigh Hopper Sub-assembly..............................................................................80

Slide Gate Sub-assembly....................................................................................81

Knife Gate Sub-assembly HD (Optional).............................................................82

Knife Gate Sub-assembly RD (Optional).............................................................83

Control Panel Layout...........................................................................................84

7-3 Spare Parts Kits ........................................................................................................85

7-4 Addendum (Service Supervisor Information) ............................................................86

Programmable Settings.......................................................................................86

Factory Setup Menu............................................................................................87

Customer Setup Menu ........................................................................................90

Factory Default Setup Parameters......................................................................92

7-5 Mitsubishi Communications Manual..........................................................................94

7-6 Technical Assistance...............................................................................................101

Parts Department ..............................................................................................101

Service Department...........................................................................................101

Sales Department..............................................................................................101

Contract Department.........................................................................................101

BF1-615.3 vi

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your
granulator. 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 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 blender 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 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. 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.

BF1-615.3 Chapter 1: 0BSafety 7 of 101

Figure 1: Safety Tags and Warning Labels

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

BF1-615.3 Chapter 1: 0BSafety 8 of 101

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.

BF1-615.3 Chapter 1: 0BSafety 9 of 101

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.

Becoming familiar with materials, inspection, speed limitations, screens, and guard
maintenance and total user responsibility will assist you in learning potential areas in need of
observation for danger.

Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, 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.

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.

BF1-615.3 Chapter 1: 0BSafety 10 of 101

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;

Note: If your blender has been inoperative or unattended, check all settings

before starting the unit.

Note: At the beginning of your shift and after breaks, verify that the controls

and other auxiliary equipment are functioning properly.

Note: 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.

Note: 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

Note: NEVER stand or sit where you could slip or stumble into the blender

while working on it.

Note: DO NOT wear loose clothing or jewelry, which can be caught while

working on an blender. In addition, cover or tie back long hair.

Note: Clean the blender and surrounding area DAILY, and inspect the

machine for loose, missing or broken parts.

Note: 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.

BF1-615.3 Chapter 1: 0BSafety 11 of 101

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.

BF1-615.3 Chapter 1: 0BSafety 12 of 101

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for slide gate
blenders of various blending rates and specifications. See below for a list of available models.

• 150 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

• 500 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

• 900 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

• 2500 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

• 4000 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

• 6000 lbs/hr Slide Gate Batch Blender with Mitsubishi Controls

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 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.

BF1-615.3 Chapter 2: 1BFunctional Description 13 of 101

Figure 2: Equipment Specifications

Dimensions and Specifications

Maximum Blending Rate, lbs / hr (k g s / h r) (3)
Number of Materials to be Bl ended 2 to 8

Slide Gate Size - Majors, in. (mm)
Slide Gate Size - Minors, in. (mm)
Supply Hopper Capacity - Majors, cu.ft. (l.) (4)
Supply Hopper Capacity - Minors, cu.ft. (l.) (4)
Weigh Hopper Capacity, cu.ft. (l.)
Typical Batch Size, lbs . (kgs)
Load Cell Capacity, kgs
Mixer Capacity, cu.ft. (l.)
Mixer Motor Size, HP (kw) 1/6 (0.124) 1/3 (0.248)
Mixer RPM 21 22
Blended Material Discharge Openi ng, in. (mm) 3.0 (76.2) 4.0 (102)
Weight of Machine (approx.), lbs. (kgs) 1100 (500)
Shipping Weight (approx.), lbs. (kgs) 1300 (590)

Approximate Dimensio ns , i n. (mm)

(1) Blender models with 7th and 8th c omponent metering include Allen Bradley 10 i nc h c olor t o uch screen standard.
(2) Compressed air loaders cannot be used to load 150 # blenders.
(3) See page 2 for important rate information concerning each model's maximum blending rate.
(4) Hopper capacity measured as level full volume. Capacity reduced when loaded automatically.
(5) Measurements describe standard unit without feeder or R.A.M. hoppers.

Height (5) 34.5 (875) 51.5 (1308) 56.5 (1435) 69.5 (1765) 85.5 (2172) 89.5 (2273)
Width (5) 26.0 (650) 37.5 (952) 37.0 (940) 45.5 (1156)
Depth (5) 22.0 (560) 37.0 (940) 40.0 (1016) 46.5 (1181)

150 500 900 2500 4000 6000

150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6 000 (2 725)

2 to 4 2 to 6

2.0 (50) 2.5 (63)

1.5 (38) 2.0 (50)

0.7 (20) 5.2 (145)

0.2 (5) 3.6 (100)

0.07 (2) 0.18 (5) 0.38 (11) 0.82 (23) 1.23 (34) 2.17 (61)

1.5 (0.7) 4 (1.8) 8 (3.6) 25 (11.3) 35 (15.8) 45 (20.4)

1 @ 5 kg 2 @ 3 kg 2 @ 5kg 2 @ 10 kg 2 @ 15 kg 2 @ 20 kg

0.18 (5) 0.25 (7) 0.56 (16) 1.1 (31)

1/8 (0.09)

42

2.5 (63)
250 (115) 375 (170) 450 (205) 650 (295)
350 (160) 475 (215) 550 (250) 800 (360)

2.0 (50) 4.0 (102)

1.5 (38) 3.0 (76)

2.5 (70) 14.3 (400)

1.8 (50) 10.2 (285)

2.72 (77)

57.5 (1461)

57.0 (1448)

Figure 3: Typical Blender Assembly

BF1-615.3 Chapter 2: 1BFunctional Description 14 of 101

2-3 Typical Features and Components

Mechanical Features

• Exclusive diamond design slide gate metering assemblies meter a large range for free

flowing pellet materials

• Adjustable Slide gate stroke limiting restrictors provided for accurate metering of

minor ingredients (not on 150#)

• Removable Stainless steel weigh hopper and mixing components

• Powder Coated Mild steel material supply hoppers with machined polycarbonate

clean-out doors and optional material drains (stainless steel on 150#)

• Precision 1/10% span accurate cantilever load cell weighing system

• Interlocked safety system shuts off compressed air and electricity if mixer is opened

• Compressed air hose with nozzle for clean-out

Figure 4: Typical Mitsubishi Controller Touch Screen Display

Note: The touch-screen panel display on your unit may be slightly different

than shown.

Controller Features

• LCD touch-screen interface display operator control panel with 32’ cable

• Target vs. actual set point verification

• Inventory accumulation for all ingredients

• Audible and visual alarms

• Auxiliary alarm contact

• 50 recipe storage book

BF1-615.3 Chapter 2: 1BFunctional Description 15 of 101

• Three (3) types of recipe entry procedures available:
o Quickset mode (up to 6-component) recipe entry. Color and additives are

metered as a percentage of the virgin material.

o Percentage mode recipe entry. Ingredients are metered as a percentage of

the overall batch.

o 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

System Component Description

This section describes the various components of the blending system.

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.

alarm if it runs out of material while

Each hopper is equipped with a sight glass and/or access door.

Figure 5: Typical Hopper Assembly

BF1-615.3 Chapter 2: 1BFunctional Description 16 of 101

Slide Gates

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.

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.

BF1-615.3 Chapter 2: 1BFunctional Description 17 of 101

Figure 6: Typical Slide Gate Assembly

Each of the diamond gate air cylinders is actuated by a solenoid valve, which are controlled
by the blender controller.

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!

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 dump door
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.

BF1-615.3 Chapter 2: 1BFunctional Description 18 of 101

Figure 7: Typical Weigh Hopper Assembly

The weigh hopper dump door holds the material until it is dumped into the mixing section.
The cylinder is actuated by a solenoid in the valve stack on the side 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 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.

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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.

Figure 8: Typical Mixer Assembly

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.

Operator Control Panel Display

The operator control panel includes a 32 foot (10.0 m) cable and can be remote mounted (not
recommended) adjacent to the blender. The panel can be unplugged and removed if
necessary.

A programmable logic controller (PLC) controls the blender operation. 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 10, 11 and 12 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 remote mount operator panel is available.

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Figure 9: Typical Mitsubishi Controller Touch Screen Display

Note: The touch-screen panel display on your unit may be slightly different

than shown.

Figure 10: Controller Pushbuttons & 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.)

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Figure 11: Typical Operator Screens

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Figure 12: Typical Setup Screens

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2-4 Optional Components

The following is a list of options, which your blender may have been equipped with:

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.

WARNING! Slide gates create a pinch-point hazard.

Figure 13: Mixer Slide Gate Switch Positions

Position Description

pneumatic slide gate

AUTO

OPEN Slide gate open all the time

CLOSE Slide gate closed all the time

Low Level Sensors

Detects material supply problems before blender supply hoppers are empty.

Mezzanine and Floor Stands

Supports blenders in mezzanine mount and freestanding applications.

Figure 14: Typical Floor Stands (Surge Hopper Stand & Gaylord Fill Stand)

Slide gate functions are automatically controlled by the blender
controller

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Regrind Auger Metering (R.A.M.) Hopper

Used for feeding difficult regrind materials.

Figure 15: Typical R.A.M. Hopper Blender Configuration

Additive Feeder Hopper

Used for feeding pelletized additive, typically used on blenders with more than six
components.

Figure 16: Typical Additive Feeder Configuration

Take-off Compartments

Allows material to be metered into a vacuum conveying system.

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2-5 Safety Features

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.

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 17 and 18). This allows the operator or maintenance personnel to

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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 17: Electrical Disconnect Plug

Twist Cap Plug Connected to Each Feeder Auger Motor

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 18: Twist Cap Plug

U ns c rew an d re m o ve p l u g

from motor

Motor

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Electric Safety Interlock Switch

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 19: Electrical Safety Interlock Switch (Located on mixer door)

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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Chapter 3: Inst allation

3-1 Uncrating the Equipment

Slide Gate/Auger Blenders are shipped mounted on a skid, enclosed in a plastic wrapper, and
contained in a crate.

1. Remove crate from around blender.

2. Secure strap of proper lifting capacity to both lifting lugs (See Figure 20 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 20: Blender Lifting Lugs (1 on each side)

3-2 Mechanical Installation

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.

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.

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