Mitsubishi Electronics 882.00207.00 User Manual 2

Gravimetric Slide Gate Batch Blender

Mitsubishi Controller

Part Number: 882.00207.00
Bulletin Number: BF1-615

Effective: 02/01/06

Write Down Your Serial Numbers Here For Future Reference:

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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________
© Copyright 2006
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 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. You should have:

; Blender

; Display (w/ connecting cable)

; Calibration Weight

; Weigh Hopper (w/ pneumatic hose line)

; 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.
Have the order number and item number available. Hold the items until you receive shipping
instructions.

882.00207.00 ii

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

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

882.00207.00 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

882.00207.00 iv

3-3

Electrical Connections............................................................................................... 34

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

3-5 Initial Set-up ..............................................................................................................35

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

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

Weigh Hopper Installation...................................................................................35

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................................................................................................ 46

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

“Quickset” Mode (Most common in injection molding) ..................................... 49

“Percentage” Mode (Most common in extrusion and blow molding) ................. 51

“Parts” Mode (Often used in Compounding Applications) .................................51

Recipe Setup.......................................................................................................51

Mixer and Dump Setup........................................................................................ 53

Alarm Flags ......................................................................................................... 55

Feeder Clean Out................................................................................................58

Recipe Book ........................................................................................................59

Color Changes ....................................................................................................61

4-3 Shut-down ................................................................................................................. 62

CHAPTER 5: MAINTENANCE ................................................. 63

5-1 Preventative Maintenance Schedule......................................................................... 63

5-2 Preventative Maintenance......................................................................................... 64

5-3 Corrective Maintenance ............................................................................................64

CHAPTER 6: TROUBLESHOOTING ....................................... 66

6-1 Introduction................................................................................................................ 66

CHAPTER 7: APPENDIX.......................................................... 71

7-1 Warranty....................................................................................................................71

Warranty Specifications....................................................................................... 71

Warranty Restrictions ..........................................................................................71

Warranty Liabilities ..............................................................................................71

882.00207.00 v

Customer Responsibilities...................................................................................71

7-2 Technical Specifications............................................................................................ 72

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

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

7-3 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

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

7-4 Spare Parts Kits ........................................................................................................85

7-5 Addendum (Service Supervisor Information) ............................................................86

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

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

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

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

7-6 Mitsubishi Communications Manual.......................................................................... 94

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

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

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

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

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

882.00207.00 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.

882.00207.00 Chapter 1: Safety 7 of 102

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

882.00207.00 Chapter 1: Safety 8 of 102

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.

882.00207.00 Chapter 1: Safety 9 of 102

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.

882.00207.00 Chapter 1: Safety 10 of 102

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.

– 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.

882.00207.00 Chapter 1: Safety 11 of 102

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.

882.00207.00 Chapter 1: Safety 12 of 102

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.

882.00207.00 Chapter 2: Functional Description 13 of 102

Figure 2: Equipment Specifications

Dimensions and Specifications

Maximum Blending Rate, lbs/hr (kgs/hr) (3)

Number of Materials to be Blended 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 Opening, 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 Dimensions, in. (mm)

(1) Blender models with 7th and 8th component metering include Allen Bradley 10 inch color touch screen standard.

(2) Compressed air loaders cannot be used to load 150 # blenders.

(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) 6000 (2725)

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

882.00207.00 Chapter 2: Functional Description 14 of 102

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 pound model)

• 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 pound model)

• 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

882.00207.00 Chapter 2: Functional Description 15 of 102

• 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

882.00207.00 Chapter 2: Functional Description 16 of 102

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.

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Figure 6: Typical Slide Gate Assembly

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

Caution! 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.

Caution! 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.

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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 you want 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 touchscreen panel display on your unit may be slightly different than

shown.

Figure 10: Controller Pushbuttons & Touchscreen Tags

Button Function

Turns power on to the blender controller.

(Power On)

(Power Off)

(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 that your blender may have been equipped with.

Pneumatic Slide Gate below Mixer

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

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

This is 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 important safety devices and procedures relating 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 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.

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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

Unscrew and remove plug

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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