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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Chapter 3: Installation

3-1 Uncrating the Equipment

Slide Gate/Auger Blenders are shipped mounted on a skid, enclosed in a plastic wrapper, and
contained in a 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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4. If equipped, adjust the four leveling bolts on the floor stand blender support rails.

5. Mount the material conveying system receivers on the top of the blender supply hoppers.

6. Align the weigh hopper on the load cell brackets. Carefully adjust the load cell brackets to

ensure that the weigh hopper is centered on the brackets without rocking. If for some reason
the locating tabs do not align with the weigh hopper, they can easily be loosened and
adjusted.

Caution! Use extreme care when tightening bolts on top of the load cells so you do not

spring the load cells. The load cells are extremely delicate and should be treated
with care!

7. Check the slide gate metering assemblies to ensure they are not damaged, and will slide back

and forth freely. These are the most important items on the blender, besides the load cell and
weigh hopper assemblies.

Site Requirements

This section describes site requirements in detail. These requirements are broken down into
mechanical mounting, electrical connections and pneumatic connections. Since the Slide Gate
Blender is available in several different mounting arrangements, it is necessary for the reader to
become familiar with the different arrangements.

Mounting Configurations

The Slide Gate System is available in (3) three basic mounting arrangements. They are:

• Machine Mount

• Mezzanine Mount

• Floor Mount

Machine Mount

In a machine mounting application of the Slide Gate unit, there are a few items to review before
placement and mounting of the blending system begins.

First, verify the machine flange dimensions match the Slide Gate blender flange (if the optional pre­drilled holes were ordered). The Slide Gate blender can also be equipped with an optional cast throat
section with a drain port. This will bolt under the bottom plate of the blender.

Verify that the machine throat is physically capable of supporting the Slide Gate blending system
with a full load of material and vacuum loading equipment installed.

Note: While in operation, the Slide Gate blender applies horizontal and vertical

pressures to the mounting flange. If there is a question as to the mechanical
stability of a mounting flange, contact the manufacturer’s engineering
department.

Verify all clearances on the top and beside the processing machine. This is to insure that all motors,
hoppers, control panels, etc. have adequate room for proper operation and servicing.

Refer to the assembly drawing with the unit for actual height and width dimensions.

Note: Allow at least 36” clearance around blender to provide adequate room for

cleaning, servicing, etc.

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Using proper lifting equipment, lift the blender, using the lifting lugs attached to the top plate of the
blender. These lifting lugs can also be used to fasten horizontal or angled braces to the blender if
more stability is needed.

Note: Larger blenders need to be braced as part of the installation.

with adequate access to operator controls, mix chamber, and metering units.

Caution! Never weld on the blender, support stand, machine or mezzanine without first

removing the control panel and verifying that the blender is properly grounded.

Mezzanine Mount

In a mezzanine mount application, review the following items before installation begins. First, verify
the Slide Gate/Auger mounting locations match the mezzanine supports. Verify that the mezzanine is
capable of supporting the blender with a full load of material and vacuum loading equipment
installed.

Note: While in operation, the Slide Gate/Auger blender applies horizontal and

vertical pressures to the mounting flange. If there is a question as to the
mechanical stability of a mounting flange, contact the manufacturer’s
mechanical engineering department.

Ensure that the gravity feed tube is installed in a vertical position, so that the materials will gravity
flow to the extruder hopper. Use aluminum tubing or smooth wall flex hose.

Figure 21: Typical Mezzanine Mounted Batch Blender

GRAVIMETRIC BATCH BLENDER

Take care to insure
proper orientation

MEZZANINE (SUPPLIED BY
CUSTOMER)

EXTRUSION CONTROL UNIT WITH
RE-LOAD VALVE
(PURCHASED SEPARATELY)

If possible, use rigid tubing. Some flex hose will tend to sag and generate static that could cause de­mixing between the blender and the extruder.

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Make sure that adequate space is around the blender (36” recommended) to allow proper cleaning,
servicing, etc.

Floor Mount (Central Blender)

In a floor mounting application, ensure adequate clearance for all blender operations and
maintenance. The operator and maintenance personnel must have access to parts of the blender. If
necessary, it is the customer’s responsibility to provide adequate, safe work platforms around the
blender to meet state and local safety codes. Using proper lifting equipment, lift the Slide Gate
blender in place.

Note: The blender must be securely fastened to the floor before operating. The

manufacturer assumes no responsibility for any damages resulting from
improper installation or improper handling during installation.

Make sure that the blender is securely mounted to the floor before installing loading equipment,
loading with material and starting.

The blender location should be an adequate distance from high traffic aisles, fork trucks, etc. that can
damage the blender. Make sure that normal day-to-day operations will not place the blending system
at risk of damage.

Figure 22: Typical Floor Mount (Central) Blender Layout

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3-3 Electrical Connections

The standard Slide Gate/Auger blending system is designed to operate on 120/1/60 supply voltage
(220/1/50 CE models are also available). The current requirements vary with the blender’s size and
throughput rating. For exact current requirements, check the blender serial number tag, located on
the rear plate of the mixer section.

If a step down transformer was provided, it should never be used to power anything other than the
blender. Loading equipment, etc. must be powered by another power source. As well as possibly
overloading the transformer, the additional equipment may induce power line noise that may affect
the operation of the blending system.

The transformer will be mounted and wired by the customer or your installer. If company or local
codes require fusing or disconnects, these items must be supplied, wired, and mounted by the
customer.

Caution! Each blending system MUST be connected to a separate source of power. Do not

connect other electrical equipment, especially self-contained hopper loaders, on
the same line as the blending system.

Ensure that the power entrance location on the blender panel remains unchanged. Make sure that the
proper size wire and proper wire routing techniques are used when installing the supply wiring to the
control panel. Care must be taken to ensure that the supply wiring does not interfere with the low
voltage DC wiring.

The blender is equipped with a plug that functions as the disconnect device (See Figure 11 on Page
27 for an example). The mating receptacle must be installed no higher than 5’ feet (1.6 m) above
the floor. Make sure your installation conforms to your regional electrical standards.

3-4 Pneumatic Connections

The Slide Gate/Auger blending system uses plant-supplied compressed air to operate the metering
and dump valves on the blender.

CLEAN AND DRY air must be supplied to the blender. The air supply should be filtered through a
5 micron air filter with a water separator. Oil should not be used unless air dryers are installed on the
compressed air supply. In this situation, an oiler may be required on the blender to keep the air
cylinder seals lubricated.

Note: This blender uses air for blender metering functions, so it is very important to

supply clean, dry air to the blender. Dirty or oily air can affect blender
accuracy, result in poor performance, and cause injury. Provide a 5-micron air
filter on the air supply to the blender, and be sure excess oil is removed. Also,
use a dedicated line to ensure proper air supply.

Figure 23: Customer-Supplied Pneumatic Components

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The manufacturer provides all pneumatic lines on the blender piped to a single ¼” NPT standard
pipe thread fitting. The Slide Gate/Auger blending system requires approximately 1 cfm (1.7 m³/hr)
@ 60 psi (4.14 bar) maximum air pressure for proper operation.

The working pressure of the blender cylinders is not to exceed 60 psi (4.14 bar). This is adjustable
by the regulator supplied on the rear panel of the blender. It is important to prevent fluctuation in the
air pressure to the blender by not installing the unit on an airline. If this is the case, an accumulator
tank with a check valve may have to be used to ensure the blender a steady air supply.

Caution! To prevent damage to the equipment, do not exceed 60 psi (4.14 bar) air pressure.

Caution! Always disconnect the compressed air supply when working on any part of the

blender.

3-5 Initial Set-up

This section will discuss the mechanical setup and control system setup of the Slide Gate blending
system. After reading this section, you should be familiar with the mechanical setup and the
electronic control setup of the blending system.

Mechanical Set-up

Stroke Limiters for Metering Gates

Stroke limiters are supplied on components 1 through 6 with all Slide Gate blenders to allow
standard metering gates to meter small amounts of low percentage additive materials.

Generally, the stroke limiter is not required on major ingredients (usually number 1 and 3) and
should be adjusted to the rear-most position. If they are used on components number 1 and 3 the
throughput of the blender will be reduced.

To install the stroke limiter, drop it into the double slot on top of the gate assembly and secure it in
place with the button head screw that is provided. Be sure to use the lock washer to prevent the
stroke limiter from coming loose.

Figure 24: Stroke Limiters

Weigh Hopper Installation

Remove the weigh hopper from the shipping box and install it in the blender on the load cell
brackets. Connect the airline and close the mixer door, securing the latch.

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Figure 25: Weigh Hopper

Note: THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE

Final Connections

1. Connect the blender to the appropriate power source.

FROM FRICTION, WITH NO MECHANICAL OBSTRUCTIONS OTHER
THAN THE LOAD CELL ITSELF.

2. Connect the compressed air piping, ensuring that a 5-micron air filter is installed, along with the
proper water trap, and lubrication unit, if required. Verify that 60 psi (4.14 bar) of clean, dry
compressed air is supplied to the blender.

Caution! Again, make sure that proper air supply connections are made to the blender, as

dirty, contaminated, wet air can damage blender components and can quickly
cause poor performance and accuracy!

Note: Make sure that the blender is supplied with clean, dry,

60 psi (4.14 bar) compressed air.

After powering up the blender the following screen will be shown:

Figure 26: Display Startup Screen

Note: It may take 45-50 seconds for the screen to appear.

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This screen displays the software version of both the PLC and the Panel View. The Controller will

p

stay on this screen for about 10 seconds or you can touch the picture of the blender to quickly skip to
the Recipe Screen (Next Screen in sequence). The software versions are also available on the Panel
View Configuration Screen.

Figure 27: Display Main (Recipe) Screen

Recipe Entry Mode

Mixer Status

Start/Stop
Blender

Immediately
Stop Blender

Accept New Recipe

New Recipe
In

ut

Feeder Type
Indicator

Go To Inventory
Screen

Go To Recipe
Book

If not, the blender can be reconfigured for Quick Set, Percent, or Parts by entering the Setup menu
and pressing the Recipe Format key. Then select the mode following the key prompt on the screen.

To access the Setup Menu to change the Recipe Mode and other controller features, refer to the
following pages of this manual.

Controller Set-up

This section describes the proper setup of the Slide Gate blending system control parameters. These
parameters are operator changeable; however, these items should only require setup during the initial
installation. Only authorized personnel should change them. For security reasons, the menu that is
used to access these parameters is password protected.

Many of the variables and setup parameters have been preset at the factory and do not need to be
changed. However, this section of the manual will address all of the blender setup parameters that
were available at the time of printing. The purpose of this is to familiarize the reader with all the
setup parameters and their usage.

A complete listing of all default values is provided at the end of this manual.

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Blender Controller Menu Structure

g

“Recipe” Page” (Start)

¾ Change Recipe Values by

touching the number you
wish to change

¾ Touch “Accept New Recipe”

button after you’ve made
the desired changes

¾ Start or stop the blender by

touching the “Push to Start”
or “Stop” button

¾ Access “Recipe Book” Page
¾ Access “Clean Out” Page
¾ Access “Inventory Page”
¾ Access “Setup” Page

“Recipe Book” Page

¾ Save the running recipe to

the book

¾ Delete a stored recipe
¾ Load a stored recipe
¾ Erase all stored recipes
¾ Modify the product ID for a

stored recipe

¾ Return to the “Recipe” page

“Clean Out” Page

¾ Empty the blender hopper(s)
¾ Manually Operate the mixer,

weigh hopper dump gate, and
the slide gate below the mixer

¾ View and test all inputs and

outputs on the blender

¾ Return to the “Recipe” Pa

“Inventory” Page

¾ View the accumulated

inventories

¾ View batch time
¾ View blender’s maximum

capacity

¾ View the average process

rate

¾ Return to the “Recipe”

Recipe Format

¾ Percentage, Parts, or Quick

Set

¾ Batch Size
¾ Inventory Shutdown
¾ “Batch ready” mode
¾ “Auto start” mode

Report Setup

¾ Blender Number
¾ “Auto clear” option
¾ “Auto interval” setup
¾ Auto start time

Calibration

e

¾ Scale Calibration
¾ Direct Scale Readout
¾ Feeder Calibration

Mixer and Dump Setup

¾ Mixing Time
¾ Remix Time
¾ Dump Time
¾ Dump Delay
¾ Dump Cycles
¾ Mixer Dump Time
¾ Timed/Continuous Mixing

Option

“Setup” Page

¾ Login from the inventory

page by pressing “Login”
and entering in your
password. Then access
setup by touching the

F940 “Config”

¾ View software version
¾ Access F940 “Config” setup to

modify time settings

Units

¾ Blender data units (lbs. or

kgs.)

¾ Target vs. actual data units

(lbs. or kgs.)

Alarm Log

¾ View and clear the alarm log

Alarm Setup

¾ “Stop/Continue” when out of

material

¾ “Alarm/No Alarm” when out of

material

¾ “Alarm Silence” delay

User Interface Lock

¾ Lock the user interface to

prevent others from making
changes or viewing your
blender. Be sure to logout
after locking.

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Blender Calibration

The load cells on the Auger blender are FACTORY CALIBRATED. Since the load cells can be
subject to shock loading during shipping, moving, etc., we recommend that they be recalibrated.

The heart of the Auger blending system is the load cell with the supply calibration weight. They
monitor the weight off each ingredient added to the blender weigh hopper. Since load cells are
reading the actual material weight that is metered by the feeders, the proper calibration of these
load cells is essential for the correct operation of the blender. This calibration must be performed
upon initial installation and startup of the blender. They should also be checked once a month with

a calibration weight and, if necessary, recalibrated to ensure that they have not been damaged
in the normal routine of removing and replacing the weigh hopper for cleaning, color changes,
etc.

The calibration of each load cell is accomplished by using two reference points on the output of the
load cell scale. The first of these points is known as the “Tare Weight.” This is the weight of the
empty hopper assembly on the load cell. This is also known as the zero weight point (starting point)
of the scale. This zero or starting point must be initialized with an empty weigh hopper. There must
be no binding or leverage put on the load cell.

The second weight point used in the load cell calibration procedure is a known amount of weight for
the weigh hopper. A calibration weight is provided with all Slide Gate/Auger blending systems. The
calibration weight is stamped with its actual weight on top. If this is not available, any object with a
known weight accurate to the nearest 1/100th of a pound, in the 2 - 10 lb. range, proportional to your
size blender, will suffice. (The weight should be as close as possible to the maximum batch size you
plan to run). The weight will be in pounds, unless the blender is set up for metric operation. In the
case of a metric blender display, the weight to be used is calibrated in kilograms.

Given the two weight points on the load cell scale, the controller should determine any other weight
on the load cell span. This is limited to the maximum capacity of the load cell. The standard load cell
used on these blenders has a span accuracy of

1

/10 %.

The maximum capacity of each load cell is clearly marked on top of the load cell. This value will be
indicated in kilograms (1 kg = 2.2 lbs.).

Note: It is not necessary to calibrate the weight scale on a brand new blender;

however, it is recommended that the calibration be checked periodically to
ensure that the reported inventory totals are accurate. Remember that in most
cases a bad calibration is worse than no calibration.

Weigh Hopper (Load Cell) Calibration

(Recommended only if the calibration is out of spec)

1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413,” then press the

“Enter˝ key.

2. Touch “Calibration” and then “Scale Calibration.”

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Figure 28: Display Calibration Menu Screen

3. Once in “Scale Calibration,” enter in the scale calibration weight value stamped on the side

of the weight.

4. The controller will prompt you to remove the weight hopper and press OK.

5. After touching OK, the controller will display “PLEASE WAIT...”

6. Next, the controller will ask you to hang the calibration weight on the right loadcell bracket

(loadcell A) and press OK.

7. The controller will ask you to hang the calibration weight on the left loadcell bracket

(loadcell B) and press OK.

8. Finally, the controller will ask you to replace the weigh hopper in the blender and press OK

to complete the calibration.

9. The controller will verify that the calibration was done correctly by showing “Calibration

Successful.”

10. Press “Done” until you have reached the Recipe screen.

Figure 29: Display Calibration Screen

Current Loadcell
Bits

Follow
Instructions

Verifying Calibration (Recommended on a periodic basis to ensure accuracy)

1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413,” then press the

“Enter” key.

2. Touch “Calibration” and then “Direct Scale Readout.”

Enter in the Calibration
Weight

Press here to perform
the calibration

Go Back to the
Calibration Directory

3. Remove the weigh hopper.

4. Locate the weight display for each of the two load cells directly below “Current Bits.”

Write down the displayed value.

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5. Add the calibration weight to each load cell mounting bracket and write down the value

displayed in “weight,” as in step 4.

6. Subtract the values recorded in step 4 from step 5. This is the measured weight. If the

measured weight is within a 0.003 pounds of the weight stamped on the calibration weight,
then you are within spec. If not, follow the steps above to calibrate the blender. (If your
blender is frequently out of calibration, verify the operator is being cautious when removing
the weigh hopper during cleanout).

7. Press “Done” until you have reached the Recipe screen.

Note: Anything in the Diagnostics Menu that is not covered here is in the Detailed

Controller Setup Section on page 33.

Feeder Calibration (Auger Blenders)

Feeder calibration should be done on all Auger blenders prior to start-up. This allows the blender to
configure the parameters which will best suit the auger size and gearbox ratio of the feeder. To
perform a feeder calibration, the operator must enter the “Feeder Calibration” screen (see menu
structure), select a feeder number, then touch “Press Here.” The feeder calibration will start
automatically and will notify the operator when complete. If the operator so desires, they can repeat
the process by entering in a new feeder number and touching the “Press Here” button.

If the blender does not see enough weight gain during the calibration process or if the weigh hopper
reaches maximum weight, then an error is given and the calibration is a failure. Another useful
feature on the “Feeder Calibration” screen is the ability to manually enter in the “weight per
second” values. This increases the blender learning process and the values can be recorded for
future blending.

Alarm Setup

This screen allows the operator to configure the alarm settings for each individual feeder. It can
configure whether a feeder will retry during the metering of a batch, and enable or disable the “Out
of Material” alarm for any feeder. If the alarm flag is set to “Stop,” the blender will not
stops on that component while continuing to try and meter. The optional low level proximity
switches have their own separate alarm. The alarm will sound, but does not
configure each hopper do the following:

1. Enter the Setup Menu.

2. Once in the Setup menu, press “Alarm Setup.” This will take you to the “Alarm Flags &

Feeder Setup” screen.

Figure 30: Display Alarm Flags & Feeder Setup Screen

Select a Feeder to
Configure

Change the Alarm
Silence Delay

3. Select a feeder (1-6) by touching the “Select Feeder” box.

continue. It

stop the blender. To

Enable or Disable
Retries

Enable or Disable
Alarms

Go back to Setup
Directory

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4. The current settings for the hopper that you have chosen will now be shown on the screen.

5. Make the necessary adjustments to the “Stop/Continue if “Out of Material,” Alarm/No

Alarm on “Out of Material,” and “Out of Material Alarm Silence Delay” (0-60 seconds)
settings. Once the settings for these features have been set on the displayed feeder, select a
new feeder to configure as desired.

6. Press the “Done” key at the bottom to exit this screen.

Network Setup

The blender’s baud rate is the speed at which data is transferred to and from the blender’s
communication port. The blender IP is the address of this blender on a network. The Slide Gate
blender is factory set up at 192 baud, with an IP address of 01.

In order to change the values, enter the Setup menu, press the “Network Setup” button and change
the values accordingly. Baud rates available are 120, 240, 480, 960, 192. Blender ID’s can range
from 1 through 255.

Figure 31: Ethernet Setup Screen

Enable or Disable
the Ethernet
Module
Configurator

Go back to Setup
Directory

Setting Date and Time

The Set Date & Time feature is located in the “Panel View Config” menu of the Setup Screen. This
feature allows the operator to set the Slide Gate/Auger Blender’s internal time clock and date. The
clock data must be entered in the traditional Hours, Minutes, and seconds. The date must be entered
in Years, Months, and Days. All values in this screen can be entered by pressing on the
corresponding button and choosing the correct number.

Figure 32: PanelView Configuration Screen

Press to set
Date & Time

Go back to Setup
Directory

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Additional Setup Parameters

The settings listed below are set at the factory and typically do not require any change.

1. From the “Recipe” Page, touch the Manufacturer’s icon and enter “5413”, then press the

“Enter” key.

Note: If the controller is set to Continuous Mixing, then the blender will run

continuously while the blender is operating. If it is set to “Timed Mixing” then
the mixer will run for the “Mixing Time” setting when a batch is dumped into
the mixer.

2. Touch the “Mixer and Dump Setup” key to enter the amount of time the mixer will mix or

the batch is dumped.

3. Enter a “Mixing Time” by pressing the number next to “sec”, this is the amount of time to

run the mixer after a batch is dumped into the mixing chamber. Remember that if the mix
time is too long you may get material separation.

4. Press the number next to “sec” on the “Remix Time” to set “Re-mix” off time. This allows

the mixer to come on between batches if the blender cycle time is very slow (i.e. if you want
the mixer to come on every minute, set this to 60 seconds). If you don’t want to use this
function, set the time to “0”.

5. Press the number next to “sec” on the “Dump Time” to set your dump time (A value

between “1” and “999” will need to be entered.). This feature is the amount of time required
to empty the batch hopper. (Set the time so that all the material in the weigh hopper has a
chance to be evacuated).

6. Press the number next to “sec” on the “Dump Delay” line for the optional dump delay

setting. This is the amount of time to start the mixer prior to dumping material into the
mixing chamber. Set to “0” to disable this feature.

7. Press the number next to “Dump Cycles” to enter the number of times that material will be

dumped from the weigh hopper. This allows the dump valve to open and shut repeatedly
when the weigh hopper is empty to shake loose any sticking material. If this feature is set to
“1” then the batch will dump normally.

8. Press the number next to “sec” on the “Mixer Dump Time” to enter the amount of time that

the mixer will run while dumping material out of the knife gate below the mixer. This
feature assists in cleaning out the mixer.

9. Press “Done” to return to the “Setup” screen.

10. Press “Alarm Setup” on the “Setup” screen to look at the “Alarm Flags & Feeder Setup

screen.”

11. This screen allows you to change the way alarms on each feeder function. Enter the feeder

you wish to configure by pressing the corresponding feeder number under “Select Feeder.”
You can select “Stop if “Out of Material” which means if there is any kind of alarm on this
feeder, the blender process will stop (i.e. the feeder supply hopper is out of material.) You
can also set it to “Continue if “Out of Material.” This mode will alarm but let the blender
continue to operate or you can set it to “No Alarm on Out of Material” mode. “No Alarm”
mode does not set off any alarms. In addition, an “Out of Material Alarm Silence Delay”
specifies the amount of time before an alarm will be set off.

12. Press “Done” to return to the “Setup” screen.

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3-6 Initial Startup

The operator can startup the blender by selecting the button that says, “Push to Start or Stop”
(startup) on the left side of the Recipe Screen, depending on whether the blender is currently running
or is stopped. Simply touch the button to either start or stop the blender. If the operator selects
“Stop Blender” then the current batch that is in progress will finish and then the blender will stop
making new batches.

To immediately stop the blender, the operator can touch “Abort Current Batch.” This will cause the
blender to stop making the current batch immediately. Obviously, if the blender is stopped in this
method then the current batch will not be completed properly.

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Chapter 4: Operation

4-1 Start-up

General Operation

The general operation of the Slide Gate/Auger blending system is as follows: once the system is
properly installed and set up, the system will be ready for operation. Please see the Installation and
Setup chapter in this manual for further information.

Once the Slide Gate/Auger blending system is powered on, the unit will display the recipe screen
(the recipe format should be in “Quickset” recipe mode). By pressing the highlighted box next to the
feeder number, the operator can enter a valid recipe or use a previously stored recipe from the recipe
book.

1. The blender is started by turning system on or material dropping below level switch in mix

chamber.

2. Metering gates are opened (or auger motors are turned on) to meter material into the weigh

hopper in the programmed order.

3. Each component is weighed, then the batch is dumped into the mix chamber (provided the

mixer “High level” switch is not covered).

4. The material is mixed in the mix chamber and flows into the processing machine.

5. The optional slide gate below the mixer may control the flow of material to the molding

machine or extruder.

Quick Start Procedure

New Recipes

1. Calibrate the weigh hopper before running the blender. (This will improve inventory

accuracy). See page 45 for calibration instructions.

2. Ensure that all ingredient supply hoppers to be used are filled with material. Virgin material

should be loaded into hopper #1 and regrind into hopper #3.

Note: On some models, Hopper #3 is equipped with an oversized square gate to assist

in the feeding of the regrind material.

3. Enter the recipe menu on the touch screen by turning on the pendant controller (It will

automatically default to this screen), and enter the blend recipe desired following the steps
listed below:

a. Touch the box (labeled 1-6) that shows the hopper you want to change.

b. Touch the “Touch Here to CHANGE” button.

c. Enter in the new value (0 to 999.99) and press the enter button (arrow).

d. Touch “Done.”

e. After you have entered the new values for all hoppers (1-6), then push the “Accept New

Recipe” button. The recipe will be entered.

The blender monitors the operator’s entries and determines if the recipe is valid before accepting the
new recipe. If there is an error (i.e. the recipe does not add up to 100% and the blender is in

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Percentage Mode.) then a message is shown on the Recipe screen to alert the operator of the
problem. The “Accept New Recipe” button is only shown if the recipe is valid and different from
what is currently running on the blender.

Recipes can also be changed while the blender is running. The new accepted recipe is entered at the
beginning of the next batch. This allows the operator to modify the new recipe without affecting the
blender until they press the “Accept New Recipe” button.

Existing Recipes

The operator can load a previously stored recipe from the Recipe Book. The Recipe book also
allows the operators to save the current running recipe. This can be done by performing the
following steps:

1. Touch the Recipe Book icon located on the Recipe Screen.

2. Select a stored recipe by changing the number next to “Recipe #.”

3. Touch “Load” and then “Done.” This will take you back to the Recipe Screen.

4. Touch “Accept New Recipe” to accept the loaded recipe into the blender.

To save a running recipe to the Recipe Book:

1. Go to the Recipe Book by touching the Recipe Book icon located on the Recipe Page.

2. Select a stored recipe by changing the number next to “Recipe #.”

3. Touch “Save Running Recipe” and then “Done.”

Note: Press “Push to Start or Stop” button to start blender.

4-2 Operation Procedures

The objective of this section is to familiarize the reader with the Slide Gate blender recipe menus,
run mode operation, run mode menus and displays. Upon the completion of this section, the reader
will be familiar with the recipes and run mode displays that are available on one blender, including
the recipe book and recipe storage facilities. Other items covered in this section are optional printer
functions and report generation capabilities of the Slide Gate/Auger blending system.

Topics covered in this section are:

• General Operation

• Recipe Menu

• Optional Printer Menu

All personnel operating the Slide Gate/Auger blending system should read this section of the manual
before operating the blending system.

Operator Displays

The Slide Gate/Auger blending system utilizes a standardized menu format. Each screen was
designed to be user-friendly and provide the operator with the necessary information to run the
blender.

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Figure 33: Typical Recipe Entry Operator Screen

A typical menu is shown in the figure above. This display, which is defaulted to when the controller
is turned on, provides the operator with the following information and options:

• The ability to change Recipe Values

• Accept a newly entered Recipe

• Start or Stop the blender

• Access to the Recipe Book

• Access to the Clean-out Screen

• Access to the Inventory Screen

• Access to the Controller Setup Screen

The menu tree shows the structure for a standard Slide Gate/Auger blender.

When the unit is initially installed the Manual Control menu will be used. This screen is primarily
used for troubleshooting the blender. All outputs can be controlled manually and all digital inputs
from the proximity switches can be viewed. Pressing the “Manual Control” key when in the “Setup”
menu accesses this screen. To gain access to the “Setup” menu, a password will be requested.

Figure 34: Typical Manual Control Operator Screen

While the blending system is in operation, there are a couple of displays available to the operator.
These displays are selected simply by pressing the “NEXT” key when the unit is running. The
default display shown when the blender is in run mode is the Recipe Screen.

The Recipe Screen indicates by feeder number, the amount of material metered into the weigh
hopper assembly by that particular feeder. This display is updated after each component dispenses its

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specified amount. The ingredient weights (Unit Values) are in pounds, unless the metric display is
selected.

Pressing the “NEXT” key when in the default recipe mode display will toggle to the next screen,
which is the Inventory Display. This can be done at any time, but if the blender is in a critical mode

such as dumping, and updating inventory, etc., it may ignore the keystroke. Simply press the
“NEXT” key again and the Inventory screen will be displayed.

Figure 35: Typical Inventory Display Operator Screen

This display indicates the amount of material in pounds that has been used by each feeder of the
recipe. It is important to note that the weights are rounded off to the closest pound. On minor
ingredients, several cycles may have to occur to show an inventory number.

In addition to showing the amount of material that has been used for each feeder, this screen is also a
summary display that shows the total inventory, the time for the last batch, and the average rate of
the blender.

If the blender is run in “Percentage Mode” instead of “Quickset” Mode during operation, the
“Percentage Mode” will use the blender inventory numbers shown on the Inventory screen to
calculate the percentages for each ingredient. It is important to zero the inventories when a recipe is
changed to have this screen accurately reflect the current percentages of the recipe in-process.

Note: Blender inventories must be cleared when the current recipe is started to show

accurate percentages for the current recipe. To clear inventories, press the
“Clear Inventory” key on the “Inventory” print screen.

Recipe Entry Formats

The Slide Gate/Auger System contains several operator friendly recipe menus. This section of the
manual lists these recipe menus:

• Recipe Page (Start/Setup)

• Recipe Book Page

• Recipe Format

Upon Start Up, the blender controller will default to the “Recipe Menu” screen.

The “Recipe Book” screen can be accessed in the “Recipe Page” and is useful in storing and
retrieving recipes.

The Recipe format option can be accessed in the Setup screen and is used to select one of three
available formats: “Quickset” Mode, Percentage Mode or Parts Mode. (“Quickset” mode is the
default setting preset at the factory). In addition, every feeder in the blending system does not need

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to have values entered (Percentage or Parts recipe formats), or a material type (REGRIND,
NATURAL, or ADDITIVE) in “Quickset” Mode recipe format.

Recipe Format Menu:

• “Quickset” Recipe, Percentage or Parts

• Metering Order

• Batch Size

• Inventory Shutdown

• “Batch ready” mode

• “Auto start” mode

• Weigh every batch options

The Recipe Format screen allows the user to change many parameters concerning the way that the
recipe is entered by the operator. It is accessed by touching the manufacturer’s icon on either the
Recipe screen or the Inventory Screen. The user must enter in the User Password to gain access (see
User Password Setup for details). The following Recipe Modes are described on the next few pages.

“Quickset” Mode (Most common in injection molding)

The “Quickset” menu structure allows recipes to be entered and adjusted by touching the buttons on
the panel face (for 1 to 6 components). In this mode, hopper #1 is configured as virgin, hopper #3 is
configured as regrind, and the others are configured as additives (i.e. color). The operator enters in
the percentage of regrind and additives and the virgin percentage is automatically calculated. The
regrind percentage represents a percentage of the total batch and the additives are based on a
percentage of the virgin weight. This is useful because the percentage of regrind can be changed
without affecting the ratio of color or additive to the virgin weight. Each percentage can be up to
100%, but not greater than 100%. The virgin percentage is automatically calculated by the blender
and the operator is not required to enter it.

The ingredient names selected will be displayed on the run mode display so that the operator will
know what material is being blended.

• The #1 hopper (“NAT” - Virgin Material) recipe ingredient will not be shown on

the recipe setup menu.

• ADD (Additive) designations will weigh the ingredient as a percentage of natural

material only.

• RGD (Regrind) designations will weigh the ingredient as a percentage of the total

batch. (It is assumed the regrind has been generated from pre-blended production
and already contains the same color and/or additives.)

• Virgin material must be loaded into hopper #1 and regrind into hopper #3.

• Component #3 is designed to handle regrind and most models come equipped with

a larger, square gate to reduce the likelihood of bridging. If regrind is being used,
it should always be run through component #3. If you don’t have regrind, another
major ingredient can be run through component #3.

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Figure 36: Example Calculations of a 5-component blend in “Quickset” mode

Virgin (NAT): ???

Additive1 (ADD): 5.00% - of virgin component

Regrind (RGD): 30.00% - of total batch

Additive2 (ADD): 2.00% - of virgin component

Additive3 (ADD): 1.00% - of virgin component

Batch Size: 10.00 lbs.

Total available: 100.00%

Regrind: 30.00%

Balance: 70.00%

Virgin + Additive 1 + Additive 2 + Additive 3 = 70.00%

Virgin + (5% of virgin) + (2% of virgin) + (1% of virgin) = 70.00%

Virgin + (5/100 x virgin) + (2/100 x virgin) + (1/100 x virgin) = 70/100

100 virgin + 5 virgin + 2 virgin + 1 virgin = 70

108 virgin = 70

Virgin = 70/108 = 64.81%

Virgin = 64.81% of batch

Additive1 = 5% of 64.81% = 3.24% of batch (5% of virgin)

Regrind = 30% of batch

Additive2 = 2% of 64.81% = 1.30% of batch (2% of virgin)

Additive3 = 1% of 64.81% = 0.65% of batch (1% of virgin)

Virgin + Additive 1 + Additive 2 + Additive 3 + Regrind = 100%

64.81% + 3.24% + 1.30% + 0.65% + 30.00% = 100%

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“Percentage” Mode (Most common in Extrusion and Blow Molding)

Extrusion processing often requires recipes in percentage format, especially if regrind is not
involved, i.e. blown or cast film.

In this mode, operators enter in values for each hopper up to 100%. The total of all the hoppers must
equal 100%. If they don’t, an error message appears on the Recipe screen and prevents the recipe
from being accepted. All hoppers are a percentage of the total batch size.

Note: All ingredients are weighed as a percentage of the total batch.

Compounding Applications)

The “Parts” recipe entry mode lets the operator enter in values based on a parts ratio rather than a
percentage. Each entry can be up to 999.99 and the total of all hoppers does not have to be 100.
After all values are entered, the total parts are calculated. The individual hopper target is then
calculated based on each hopper’s entered parts. These parts represent ratios of the total batch. For
instance: Hopper 1=300 parts, Hopper 2=100 parts, Hopper 3=10 parts, Hopper 4=5 parts. This
would mean that if the batch was divided into 415 parts, then Hopper 1 would make up 300 of those
parts, Hopper 2 would make up 100, Hopper 3 would make up 10 parts, and Hopper 4 would make
up 5 parts.

Note: The preset part will be divided by the total of all parts, with each part

representing the calculated weight for ratio control.

Figure 37: Example Calculations of a 4-component Blend in “Parts” Mode

Feeder Tag Preset Part

Virgin #1 7,200 7,200/10,000
Regrind #2 2,000 2,000/10,000
Color #3 500 500/10,000
Additive #4 300 300/10,000
Total: 10,000

Calculated Weight
(Ratio Control)

“Parts” Mode
(Often used in

Current Recipe Menu

Throughout the menu structure, the top left corner of the display will list the name of the current
screen that you are in. Each individual button will indicate instructions for keystrokes. In the Recipe
Format menu shown on the previous page, pressing on the mode button displayed at the top of the
screen will show the Current Recipe menu.

Note: The blender will always run the percentages shown in the Current Recipe

menu display.

Switching Modes

Recipe Modes can be switched while the blender is making a batch. At any time the operator can
switch the recipe entry mode without affecting the current batch being made. The recipe mode is
part of the “New Recipe” and is separate from the running recipe.

Recipe Setup

Batch Size

The Slide Gate/Auger blending system is a gravimetric batching system. The blender will weigh a
preprogrammed batch of material each cycle. This batch size is determined by the blender’s weigh
hopper size, the current recipe, and the bulk density of the ingredients.

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Because the blending systems must handle a wide variety of materials with varying bulk densities,
the actual amount of weight of material the weigh hopper will hold can vary dramatically from
application to application.

This feature allows the operator to change the size of the batch to be made. A value will need to be
entered between 0.5 and 99.9. This can also be changed while making a batch without affecting the
current running batch. If the size is changed then you will need to touch “Accept New Recipe” on
the Recipe screen before the change takes place. This feature allows stored recipes with different
batch sizes to easily be loaded without the operator having to reconfigure the blender every time they
want to load a stored recipe.

The weigh hopper size selected should be one that approaches the maximum capacity of the load
cells without over-filling the weigh hopper. During the initial setup of each blender, the weigh
hopper size setting should be checked to ensure that the weigh hopper is not overfilling due to a
large percentage of light weight regrind, etc. The batch size will vary from model to model. The bulk
density of the material being blended will also affect the batch size.

Note: If running a high percentage of lighter density regrind, set the batch size so

that the mixer does not overfill, preventing the weigh hopper from fully
dumping when operating in “Batch Ready Mode.”

Figure 38: Typical Batch Sizes

Blender Batch Size (lbs.)

150 1.5
500 4.0

900 8.0
2500 25.0
4000 35.0
6000 45.0

Inventory Shutdown

In many applications, the user of the Slide Gate/Auger System produces large runs of blended
material on the same recipe during production. An example may be a 40,000-lb. run of a certain
specification plastic extrusion. Others may wish to fill a 1,000-lb. gaylord box in a central blending
application. In either case, the manufacturer has provided a means to automatically stop the blending
system when the blended material has reached a preset total blended weight. This is known as
Inventory Shutdown.

When the Inventory Shutdown value is reached, the blender will finish the current batch of material.
It will then stop and display to the operator that the inventory value has been reached. Additionally,
it will flash an alarm and wait for operator attention. An example of this screen is shown below:

Figure 39: Typical Blender Shutdown User Prompt Operator Screen

Touch to make
another box of
material

Touch if you don’t
want to make another
batch

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To enable this feature, simply enter a desired shutdown weight value (from 1 to 999999999) into
the Inventory Shutdown display line of the Recipe Format screen, under the Setup menu.

This feature can be configured while the blender is making a batch. If the Inventory Shutdown is
changed, then you will need to touch “Accept New Recipe” on the Recipe screen before the change
can take place. This allows stored recipes with different Inventory Shutdown settings to easily be
loaded without the operator having to reconfigure the blender every time they want to load a stored
recipe.

To disable this feature, simply enter a zero (0) value.

Batch Ready Mode

This enables the blender to have a batch already made in the weigh hopper while the mixer is full.
Enabling this feature dramatically increases the maximum achievable blender rate.

Auto Start Feature

By enabling this feature, the blender accurately finishes a batch that was interrupted by loss of
blender power. This option starts the blender if it was running prior to power loss. It does not turn
on the blender if it was previously stopped prior to power loss.

Mixer and Dump Setup

Mixer Options

Press the “Timed/Continuous Mixing” key (in the top right hand corner) when in “Mixer and Dump
Setup” screen to set the following options:

Timed Mixing Option

This mode of operation turns the mixer on only during dumping and during the re-mix time set
into the control to jog the mixer during high level mixer operation.

Continuous Mixing Option

This mode of operation turns the mixer on after initial startup and will continue to run unless the
remix time is set to jog the mixer during high level mixer operation. This option is used for
sticky materials that tend to bridge and block off the mixer discharge to the processing machine.

Mix Timer

The mix timer is the amount of time that the mix motor will mix the material after it has entered the
mixing section of the Slide Gate/Auger blender. The timer has a range of 1 to 999 seconds.

To set the value of the mix timer, the user must gain access to the Setup Menu. After entering the
Setup menu, the user must select “Mixer and Dump Setup.”

Figure 40: Typical Mixer and Dump Setup Operator Screen

Go Back to Setup
Directory

Selecting “Mixing Time” from the “Mixer and Dump Setup” menu will allow the operator to view
the current time setting for the mix timer and to adjust it as needed.

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The mix timer is set to a default time of four (4) seconds. This time can be adjusted up or down
depending on the amount of mixing needed for the materials being blended.

It is recommended that the mix time be held to the minimum, as segregation can occur from over­mixing if the material bulk density and pellet configuration varies with materials in the particular
blend being processed.

Re-Mix Timer

In some applications, the Slide Gate/Auger blender will require the use of the re-mix timer. Some
materials tend to separate if they are mixed too long. This is possible when a processing machine is
running at a rate significantly below the capacity of the blender.

With external vibration, the heavier pellets will tend to flow to the bottom of the mix chamber before
the lighter material. This will occur even though the mixer is in a static mode. By re-mixing
occasionally, this situation will be prevented.

The re-mix timer will start another mixing cycle if the blender has been idling long enough for the
re-mix timer to time out. The re-mix timer may be set on the “Mixer and Dump Setup” screen from 1
to 999 seconds. Setting the re-mix timer to zero will disable this function.

If the re-mix timer is disabled, the controller will run only a single, timed mix cycle after each dump
of the weigh hopper.

To view and change the value of the re-mix timer, refer to the “Mixer and Dump Setup” menu. All
current values for Mixing and Remixing Times will be shown on this screen. The re-mix timer
default value is factory preset at zero.

Weigh Hopper Dump Time

The weigh hopper dump time is the amount of time the weigh hopper’s dump valve remains open to
allow weighed material to exit the hopper and enter the mixer.

To view and change the current weigh hopper dump time settings, enter the Setup menu and select
the “Mixer and Dump Setup” screen. Press the field next to “Dump Time” to set the operation of the
Dump Valve.

The dump timer on the dump valve has a default time of four (4) seconds. This time can be adjusted
to optimize the blender cycle time.

The timer should be set to close the dump valve shortly after the material has completely dumped
from the weigh hopper. This time can vary due to material flow characteristics and the size of the
batch that is programmed into the blender control. Experimentation with this setting can allow the
operator to determine the best cycle for the material being weighed.

Weigh Hopper Dump Delay Time

The dump delay time is the amount of time from the end of metering the last ingredient until the start
of the actual dump cycle. The start of the dump cycle is marked by the opening of the weigh hopper
dump valve. This value has a range from 1 second to 999 seconds. To view and change the current
dump delay time, enter the Setup Menu, select “Mixer and Dump Setup” screen, and then select
“Dump Delay.”

The default time is factory set at zero seconds. This delay time is used to start the mixer prior to
dumping the material from the weigh hopper into the mix chamber of the blender.

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Weigh Hopper Dump Cycle

The dump cycle allows the weigh hopper dump valve to cycle or open and close a number of times
prior to commencing with the next batch cycle. The setting allows from 1 to 9 dump cycles between
batches (open and closed cycles).

The normal and default factory setting is 1, meaning the weigh hopper dump valve will open at the
end of the weighed batch and close after the batch is discharged into the mixer.

Setting the dump cycle to more than one cycle may be useful when blending high static, dusty
material or those that have sticky tendencies. This will cycle the dump valve open and closed to
allow any material that may cling to the dump valve.

To enter the dump cycle menu, first enter the Setup menu by pressing the Manufacturer’s icon from
the main menu. Enter the password and press enter. Next, press the button marked “Mixer and Dump
Setup.” The display will show the “Mixer and Dump Setup” menu. Press the “Dump Cycle” key to
enter a dump cycle value and press enter. Please refer to the menu structure tree shown in section 3-

5.

Mixer Dump Time

The mixer dump time is the amount of time the knife gate below mixer’s valve remains open to
allow blended material to exit the blender.

To view and change the current mixer dump time settings, enter the Setup menu and select the
“Mixer and Dump Setup” screen. Press the field next to “Mixer Dump Time” to set the operation of
the Dump Valve.

The dump timer on the dump valve has a default time of six (6) seconds. This time can be adjusted
to optimize the blender cycle time.

The timer should be set to close the dump valve shortly after clearing the high-level sensor. This
time can vary due to material flow characteristics and the size of the batch that is programmed into
the blender control. Experimentation with this setting can allow the operator to determine the best
cycle for the material being mixed.

Alarm Flags

An alarm message will be shown if any alarm condition occurs. A message will pop up on the
screen until the alarm condition is resolved. The operator can press “OK” on this pop-up to hide the
screen temporarily, but if the alarm condition is still unresolved, then the message will reappear after
a short delay. During an alarm condition, not only will a visual alarm show up on the screen but also
an audible alarm will sound. The audible alarm will sound for 10 seconds and reappear every 30
seconds until the cause of the alarm is resolved. The following is a list of all alarm names and
descriptions:

Hopper 1-6 Out of Material

This alarm indicates that a hopper is out of material and signals the operator that they should check
the resin system.

Typical “Out of Material” Alarm Screen

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Max Hopper Weight Exceeded, Check Batch Size

This alarm indicates that the weight in the weigh hopper has exceeded the maximum allowed weight.
This alarm can happen if the operator changes material density and does not perform a feeder
calibration, but will usually be automatically fixed after the first batch. As long as this alarm doesn’t
continue to reappear, then the operator should not be concerned. If the alarm continues to occur,
then the operator should have maintenance check the blender.

Calibration Error, Clean out Hopper and Check Calibration

This alarm indicates that the maximum empty weight for the weigh hopper has been exceeded. The
blender will automatically tare up to 0.25 lbs of material, but if this weight is exceeded, then an
alarm will appear. This alarm is most commonly caused by a build up of sticky material in the
weigh hopper and can be corrected by simply cleaning out the weigh hopper. If this does not correct
the problem, then the scale calibration should be checked by maintenance.

Typical “Maximum Hopper Weight” Alarm Screen

MAX HOPPER WEIGHT

EXCEEDED

check batch size

Typical “Calibration Error” Alarm Screen

CALIBRATION

Power Interruption while metering a Batch

This alarm indicates that the blender’s power was turned off while the blender was making a batch.
The batch accuracy is not affected as long as the blender is configured for “AutoStart.” The blender
will finish the last batch accurately even if the material was dumped into the mixer when the power
was turned off.

Typical “Power Interruption” Alarm Screen

POWER INTERRUPTION

While metering a

Batch

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PLC Battery Low

PLC battery is low and may cause the blender to lose both the program and the blender
configuration. Notify Maintenance immediately.

Typical “PLC Battery Low” Alarm Screen

PLC BATTERY LOW

Blender Powered On/Off

These are only logged in the Alarm Log and does not cause a pop-up message or audible alarm.
Each time the blender is powered on or off, the time and day is logged to the Alarm Log.

Inventory Cleared

This is only logged in the Alarm Log and does not cause a pop-up message or audible alarm. Each
time the inventory is cleared, the time and date are logged to the Alarm Log. An alarm will sound
and a screen will pop up when Auto. Inventory Shutdown has been reached.

E-Stop Screen

The blender is equipped with an E-stop switch that removes the power from all mechanical outputs.
The E-Stop Screen appears along with an audible alarm whenever the E-Stop is activated. The
operator cannot access any screens until E-Stop is deactivated. The Panel View will then put the
screen back to the display that the operator was on prior to pressing the E-Stop button.

Typical “E-Stop Activated” Alarm Screen

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Feeder Clean Out

Any feeder in the Slide Gate/Auger blending system can be emptied and refilled with a different
material. To do a feeder clean out, the operator has to press the “Clean Out” icon key from the recipe
screen (the first screen that appears when powered up).

This screen will allow you to Open or Close the Feeder, Weigh Hopper, Mixer Knife Gate, Empty
the Entire Blender, Start or Stop the Mixer Motor, Test the Alarm Output, Find out the Mixer
Proximity Status and monitor the Current Hopper Weight.

Figure 41: Typical Manual Control Operator Screen

Test Alarm

Open or Close
Feeder

Output

Empty Entire
Blender

Open or Close
Weigh Hopper

Start or Stop Mixer
Motor

Open or Close
Mixer Knife Gate

Low Level Prox
Status

Warning Message

Current Hopper
Weight

Go back to Setup
Directory

The dump valve opens as soon as the “Press to Open Feeder” key is pressed. This easy feeder clean
out option also serves as a means for emptying a batch that is held in the weigh hopper if the “Press
to Open Weigh Hopper” key is pressed when the blender is stopped. To open/close feeder numbers
2, 3, 4, 5 & 6 press the number next to “Press to Open Feeder” to select the feeder you desire to
empty and the “Press to Close Feeder” key to close the dump valve. Touch the “Done” key to return
to the recipe menu. After entering a recipe, the operator will restart the blending system, putting it
back in normal operation.

Note: Before starting Slide Gate/Auger blending systems, each ingredient hopper in

the current recipe must contain material! Virgin material must be loaded in
hopper #1. Hopper #3 should only be used for regrind!!

Once the operator initiates the run mode of operation, the blending system controller will begin
monitoring the mixer high-level switch. Nothing will happen until the mixer high-level switch is
uncovered. This tells the controller that the mixing chamber is capable of holding another batch of
material.

Once the mixer high-level switch is uncovered, and the weigh hopper has dumped, the system will
meter the ingredients from the supply hoppers, through the metering units, into the weigh hopper.
Each component will be metered individually to allow accurate weighing of the material.

Each component is metered in the order specified by the “Metering Order” setup. See the Installation
& Setup chapter for further details.

Once the final ingredient specified in the recipe has been metered into the weigh hopper, the
controller will take a final weight reading of the weigh hopper. This will start the “Dump Delay”
timer (See Page 51). Once the dump delay timer has timed out, the controller will activate the weigh
hopper dump valve, initiating the weigh hopper dump cycle.

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The open weigh hopper dump door will allow the material to drop into the mixer section of the
blender. If the dump delay is set, the mixer will start before the weigh hopper dump will open for the
selected time.

The blender will sit at rest until the high-level sensor in the mixing chamber is uncovered to start
another weigh cycle. (Unless the Re-Mix timer is set to a value other than 0 and times out, restart the
mixer to run for another mix cycle).

The level sensor is located on the back wall of the mixer chamber. If the sensor is covered with
material, the indicator light on the back of the sensor will be lit.

Once this sensor is uncovered, the indicator lamp on the back of the level sensor will go out. This
level sensor must be uncovered for approximately 1 - 2 seconds to indicate to the controller that
there is room in the mixing section to accept a batch of material.

When the controller has determined that the mixer is ready for an additional batch of material, the
controller will begin metering material into the weigh hopper assembly.

Recipe Book

In many applications, it is favorable to hold several recipes in the memory of the blending system.
The Slide Gate/Auger blender has provided for this by incorporating the manufacturer’s recipe book
software.

The recipe book is capable of holding 50 different recipes. These may be stored and recalled by
number. During this section of the manual, the operator may wish to revert to the Menu Tree

Diagram in section 3-5 of this manual.

It is important to note that the recipe book only stores and recalls recipes. The blender will operate
on the current recipe only, so a recipe must be recalled from the book to the current recipe for it to

become active.

Each recipe stored in the recipe book may be displayed and/or modified. Only the current recipe
will be blended.

Always verify that the Current Recipe is showing what you want to run, and that the correct
recipe has been downloaded from the book.

The recipe book section contains the following Items:

• Save Running Recipe to the Book

• Load a Stored Recipe from the Book

• Display a Stored Recipe

• Erase One Recipe or the Entire Recipe Book

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Figure 42: Typical Recipe Book Operator Screen

Select a Stored
Recipe

Stored Recipe
Details

Save Running Recipe to the Book

The save current recipe to book function allows the operator to save the contents of the current
recipe to the recipe book under a desired number.

Upon selecting this function, the operator will be prompted for a reference recipe number. This may
be any number from 1 to 50.

The assigned recipe number will be used for all further references to this recipe until deleted. The
operator should be familiar with the recipe numbers used. We suggest keeping a loose-leaf notebook
with 50 tabbed pages as a reference to what is kept in the blender so this can be the standard for all
blenders in the plant, etc. To save a running recipe to the Recipe Book perform the following steps:

Erase One
Stored

Recipe

Erase Entire
Book

Load Stored
Recipe

Go to Recipe
Page

1. Enter the Recipe Book by touching the Recipe Book icon located on the Recipe Screen.

2. Select a stored recipe by changing the number next to “Recipe #.”

3. Touch “Save Running Recipe” and then “Done.”

Load a Saved Recipe from the Book

The load from book function allows the operator to retrieve a previously stored recipe from the
recipe book and install it into the current recipe menu. This will overwrite the current recipe, so
make sure that it has been saved to the book before installing a new recipe in its place. To load a
previously stored recipe from the Recipe Book:

1. Enter the Recipe Book by touching the Recipe Book icon located on the Recipe Screen.

2. Select a stored recipe by changing the number next to “Recipe #.”

3. Touch “Load” and then “Done.” This takes you back to the Recipe Screen.

4. Touch “Accept New Recipe” to accept the loaded recipe into the blender.

Note: If replacing the current recipe with one that is downloaded from the Recipe

Book, make sure that the previous recipe has been saved because it will be
overwritten by the new downloaded recipe.

Display Recipe Contents

The display recipe function is used to verify the contents of a recipe number before it is loaded from
the recipe book. In order to view the desired recipe, the operator must enter the number which
contains the recipe he wishes to view. Once a valid recipe number is entered, the display will
indicate the contents of the stored recipe in percentages.

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Erase Recipe or Entire Book

The Erase Recipe or Entire Book function is used to eliminate old or outdated recipes from the
recipe book. If the operator only wants to delete one recipe, the configuration for that recipe should
be currently displayed on the screen. The controller will only prompt the operator if they want to
erase the entire book when that key is pressed. Once a recipe number is deleted, the contents of that
recipe are lost. The recipe number may be used again in the future for new recipes.

Color Changes

The color change procedure is meant for use with the basic Slide Gate/Auger Blender. This
procedure assumes that the color component of the blend is in an additive ingredient hopper (#2, #4,
#5, or #6).

Note: The blender must be stopped to make color changes. The processing machine

can operate on virgin material only during this procedure with an optional
quick color change bypass tube that can be installed to bypass the blender.
Contact the factory for details.

1. Disable and clean any color loading equipment. Please refer to the loading equipment

manual for any clean up recommendations.

2. Using the blender “Abort” or “Push to Start or Stop” key put the blender in stop mode. After

the cycle has completed, switch “OFF” the main power switch and unplug the blender power
supply.

3. Open the upper mixer access door. This shuts off air to the blender circuit by deactivating

the master air valve. Then unplug the quick disconnect from the air supply hose to the
blender to further ensure that no air pressure is supplied to the blender.

WARNING! Always unplug the main power cord and disconnect the air supply to the blender

prior to performing any operations inside any access areas of the blender where
there are moving parts.

4. Remove the weigh hopper by unplugging the air line disconnect fitting, holding the dump

door closed, lifting the hopper to clear the load cell brackets, and gently pulling the weigh
hopper out of the blender.

Caution! To reduce the chance for damage to delicate load cells, use care when lifting the

weigh hopper off load cell locating tabs and when reinstalling the weigh hopper
on load cell brackets.

5. If you want to catch the color, use a small plastic pail or chute to collect the material from

the slide gate assembly. Reach up inside the blender to the color slide gate and push it open.
At this point, there should be no air pressure on the blender, and the slide gate should move
easily. Drain the color out in the bucket. Blend and Reclaim normally provides a JIT (Just in
time) approach to the minor ingredients, so that a minimum amount of material is held in the
blender so that color changes can be made easily.

6. If any other ingredients need to be changed for the next recipe, simply drain the larger

hoppers with the drain tubes provided on the side of the hoppers. When the material level is
below the drain tube, open the slide gate manually to dump the rest of the material. If you
wish to speed the emptying process, material can be manually drained out of the slide gate
assembly into a dump chute or bucket, while draining from the drain tube.

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7. Using a vacuum cleaner or air hose, clean out all the hoppers that have been emptied.

Always start at the uppermost part of the blender and work downward to prevent dust and
pellets from falling into an already cleaned area.

WARNING! The auger metering assemblies on Auger blenders can be removed after the

8. Clean the weigh hopper and mixer assemblies on the blender using a vacuum cleaner. The

mixer agitator is removable for cleaning if desired.

9. Reinstall any metering units that were removed from the blender during clean out.

10. Reinstall the weigh hopper using care to center the hopper on the load cells on the weigh

hopper bracket.

11. Load the blender with new material.

12. Restart the unit with the new recipe.

DANGER! Always disconnect and lockout all electrical power and pneumatic (i.e.

4-3 Shut-down

The Slide Gate Gravimetric Blender can be stopped in one of two ways:

hoppers above them have been drained.

compressed air) sources prior to servicing or cleaning any product, including all
Slide Gate/Auger blending systems. Failure to do so may result in serious injury
or death.

1. To immediately stop the blender, the operator can touch “Abort Current Batch.” This will

cause the blender to stop making the current batch immediately. Obviously, if the blender is
stopped in this method then the current batch will not be completed properly.

2. If you would like to complete the current batch of material before shutting down, then you

can wait until the Inventory Shutdown value is reached. The blender will finish the current
batch of material to the specifications set in the Setup portion of this manual. It will then
stop and display that the inventory value has been reached. Additionally, it will flash an
alarm and wait for operator attention. An example of this screen is shown below:

Figure 43: Typical Inventory Shutdown Operator Screen

Touch to make
another box of
material

Touch if you don’t
want to make another
batch

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Chapter 5: Maintenance

5-1 Preventative Maintenance Schedule

The mechanical design of the blender is very simple and very little maintenance is required. The
only moving parts are the metering gates, weigh hopper dump valve, and mixer agitator. The
checklist below contains a list of items which should be inspected and/or replaced to keep your
blender operating at peak efficiency. Perform each inspection at the regular intervals listed below.

Figure 44: Sample Preventative Maintenance Schedule

System model #

Daily

any loose parts­tighten them
immediately.

Verify quality of
compressed air
supply.

Verify mixer door is
properly latched.

Every week

Inspect metering
gates for proper
operation.

Serial #

Date/

Date/

Date/

Date/

Date/

Date/

Date/

Date/

By

By

By

By

By

By

Inspect blender for

Date/

Date/

Date/

Date/

By

By

By

By

By

Date/

By

By

Date/

By

Date/

Date/

By

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Date/

By

Check to make
sure that all hose
connections are air
tight.

Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Inspect air regulator
and air safety
circuits, if equipped.

Recalibrate blender
only If necessary.

Photocopy this page for your maintenance records

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5-2 Preventative Maintenance

Our blenders need periodic maintenance to provide long dependable service. Check these elements
regularly:

• Check functionality of safety circuit daily.

• Maintain proper air pressure and drain water from trap assembly on regulator – as required.

• Periodically lubricate slide gate rails.

WARNING! Always remove plug and disconnect power before servicing blender.

WARNING! Always read operating manual before operating or servicing blender.

5-3 Corrective Maintenance

Electrical

This section is designed to give the operator an overview of the electrical system that controls the
Slide Gate/Auger blending system. Since the blender’s control panel is a self-contained pluggable
item, seldom will a maintenance person be required to enter the control panel. For purposes of
understanding the system, it is advisable that the maintenance personnel be familiar with not only the
internal workings of the control panel, but also with the input and output signals to the Slide
Gate/Auger blender.

This section includes the following:

• Internal components of the control panel

• Input signal to the control panel

• Output signals from the control panel

Internal Components of the Control Panel

Note: See Installation Packet supplied with unit for complete electrical schematics.

This section describes the internal components of the Slide Gate/Auger blending system control
panel. It is not the intent of this section to completely familiarize the reader with the details on
industrial control panel construction or standards, but simply to familiarize the reader with the major
components inside the control panel.

The customer must supply 120/1/50 or 60 (or 220/1/50 or 60) via wires L1 & L2 (N). Please ensure
that the earth ground connection is properly connected to an established earth ground.

• “Power on” is indicated by a lighted on/off switch.

• “Slide gate below mixer” switch controls position of optional slide gate.

• “Safety Active” light displays status of safety interlock circuit. Audible alarm horn alerts

operator to blender fault.

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Input Signals to Programmable Controller

The Slide Gate/Auger blending system has two main input signals that it uses from the blending
process: the mix hopper high level signal and the weigh hopper load cells. This, of course, does not
include the operator touchscreen input.

The mix hopper high level signal is generated by a proximity level sensor located in the right hand
portion of the mixer chamber (viewing from the mixer door).

Load cells require +10 volts DC to operate. This is known as the load cell’s excitation voltage.

Output Signals from Programmable Controller

The Slide Gate/Auger blending system uses several output control signals to control the process. All
of these are very similar in nature, the first of which is the mixer motor control.

The mixer motor is controlled by a PLC output.

The weigh hopper dump valve output functions similar to the mix motor output. Please refer back to
the wiring diagram. The origin of the weigh hopper dump signal is a PLC output.

The auger motor outputs are driven from a control output from the PLC.

Each blending system includes an auxiliary customer alarm output. This dry contact can be used to
switch a remote alarm signal.

The customer alarm output is provided to actuate or energize a variety of alarm horns, buzzers,
strobe lights, and beacons. These are normally provided by the customer, and care will have to
be exercised not to exceed the maximum current draw (3 amp maximum). The contacts will
close whenever the control detects a fault that will somehow inhibit the blending system from
properly blending the material.

Note: The customer alarm contact is open if the panel control power is turned off.

This contact is for use with a customer supplied alarm device as described
above. The alarm contact has a maximum load of 3 amps.

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Chapter 6: Troubleshooting

6-1 Introduction

The utmost in safety precautions should be observed at all times when working on or around the
machine and the electrical components. All normal troubleshooting must be accomplished with the
power off, line fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be overemphasized when troubleshooting is indicated.
Use a good ammeter that can measure at least twice the AC and DC current that can be encountered
for the machine. Be sure that the voltmeter has at least minimum impedance of 5,000 OHMS-per­volt on AC and 20,000 OHMS-per-volt on DC scales. Popular combination meters, VOM and
VTVM can be selected to provide the necessary functions.

Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for other
defective devices. It is common to replace the obviously damaged component without actually
locating the real cause of the trouble. Such hasty substitutions will only destroy the new component.
Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When necessary,
refer to the parts catalog section.

Figure 45: Typical Troubleshooting Problems and Suggested Corrective Actions

Problem Corrective action

Check to make sure that air is hooked up and the regulator gauge
reads at precisely 60 PSI.

Nothing happens when I push
“Start Blender”

Check that the access door to the mixer is shut properly.

Look on the Recipe Screen. If you see “Mixer Full”, then check
the mixer. If the mixer is not full, then check that the mixer prox
is adjusted properly (small screw on back).

“E-STOP has been Activated”
is shown

“Interface has been Locked” is
shown

I’ve forgotten my User
Password

POWER INTERRUPTION
ALARM

PLC Battery Low

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Check the E-Stop located on the front of the blender panel.

Click “Unlock” and enter in your User Password.

Contact the Service Department.

Power was lost during a batch. Check your power source unless
you intentionally interrupted the power during the batch.

Change out the PLC with your spare and reprogram new unit.
Send old PLC back to manufacturer for repair.

Problem Corrective action

Normal after a software upgrade. Follow on-screen instructions.

Check the input power. Verify that 110 volts (or 220 volts) are
±10%. This voltage must remain constant with all the motors
starting and stopping. Insure that the blender is on a “clean” circuit
that does not have other equipment on it. If the power is known to
be intermittent and have problems, set up the unit to run in
“AutoStart” mode. See the factory setup sheet at the end of this
manual. In this mode, if a short power interruption occurs, the

PLC Module Loaded

Weigh hopper occasionally
overfills.

blender will automatically restart.

Check the power supply. Make sure that it has +5 VDC output to
the CPU board. Adjust to +5 VDC, ±0.1 volt.

Check the display ribbon cable connection to the CPU board and
the display. See the electrical chapter for more information.

Check the contrast adjustment located on the display board.

Check keyboard ribbon cable connections.

Check the CPU board for “lockup.” To do so, reset the CPU board
by cycling the power off and on at the motor control panel.

Check batch weight setting in the recipe menu. See the setup
chapter for more information.

Check the load cells and weigh hopper mounting for binding, etc.

Check to see that a pellet is not lodged under a load cell.

Check the ingredient supply hoppers to verify proper ventilation. If
a vacuum receiver has a leaking flapper valve and the supply
hopper is not vented, the blender computer can learn inaccurately
and cause an overfill condition on the next few cycles.

Check the load cell connections to the panel.

Check the mix timer setting. This problem is normally due to over
mixing. See the mix timer section in the setup chapter. Reduce the

Material tends to separate in the
mixing chamber.

Material sticks to the flapper of
the weigh hopper and is not
dumped.

Too much material remains in
the mixer.

The material is not being mixed
thoroughly.

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time until the problem is corrected.

Check the mixer drive to ensure that the agitator is turning
properly.

Check the high level switch in the mixer to lower the level slightly.

Increase the Dump Cycles setting in Mixer and Dump Setup.

Increase the Mixer Dump Time in Mixer and Dump Setup.

Increase the Mixing Time in Mixer and Dump Setup. However, if
you over mix material, you can have the same problem. If you
have the blender set for “Continuous Mixing” then change it to
“Timed Mixing” and adjust the Mixing Time appropriately.

Problem Corrective action

Check the blender’s scale calibration and verify that the batch
hopper is not overfilling. If the hopper is overfilling, adjust your

Recorded Inventory Totals don’t
match what I’ve actually used.

batch size. If this is correct, then you are probably not accounting
for material scrap or other items in your process.

Some error can be introduced by not weighing every batch. Check
the Recipe Page.

Max Hopper Weight Exceeded
Alarm continues to re-occur.

Blender occasionally dumps an
incorrect batch.

Blender keeps dumping after
mixer is full.

Stop the Blender and the Start it again. This causes the blender to
perform an automatic feeder calibration. If this doesn’t fix it, then
manually perform feeder calibrations and retest.

The blender intermittently dumps a batch of material with one or
more of the components incomplete.

Check the recipe information; ensure that both the percentages and
batch size are set properly.

Check the status of the alarm flags & Feeder Setup to ensure that
all of the feeders are set to Retry. In addition, if the blender is
configured for timed batches then this can cause error.

Check supply hopper ventilation to prevent problem associated
with leaky vacuum receiver flappers.

Check the mixer high-level switch sensitivity. When the sensor is
covered by material, the indicator lamp on the back of the switch
should be lit. To adjust the sensitivity, use the small adjustment
screwdriver that was provided with the blender. The adjustment
pot is located on the back of the sensor. Rotate clockwise to
increase the sensitivity (less material in front of the switch to
actuate it). Rotate counter clockwise to decrease the sensitivity
(more material covering the switch).

Check the mixer high-level sensor connection to the control panel.

Check the mixer high-level switch sensitivity. Fines may have
coated the level switch; it needs readjustment.

Blender will not batch with
empty mixer.

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Check the proximity switch connection.

Make sure that the recipe is correct.

Check batch size.

Problem Corrective action

Check the Mixer and Dump Setup to see if the mixer is configured
for “Continuous Mixing.” Set it to “Timed Mixing.”

Check the value of the mixer timer setting.

Check the value of the dump delay timer.

Check the mixer motor fuse. This is located in the control panel on
the SSR for the mixer motor. If the unit has two (2) power inlets
with a separate power inlet for the mix motor the overload fuse
will be located in the rear junction box on the blender frame.

Check the power source to the blender.

Check the load cell in diagnostics under direct scale readout. Place

Mixer won’t shut off and runs
continuously.

a calibration weight on the weigh hopper; determine if the weight
corresponds.

Check the load cells to make sure that a pellet is not jammed under
a load cell.

Check the load cell connections to the control panel

Check the power supply voltage and readjust as necessary as
described earlier.

Check the memory battery voltage on the CPU board. If the
battery is dead, the blender “forgets” settings when the power is
off. Replace it with a new battery. Order a spare CPU board and
send the replaced one back to the factory to have a new battery
holder and battery installed. If this is done in the field, the
controller warranty will be voided.

“Out of Material” Alarm is
displayed, but there is material
in the hopper.

I’m not getting Out of Material
Alarms.

Calibration Weight Exceeded.

The feeder calibration values
are moving too much.

Go to the Manual Control Page and check to see if “Hop Low”
equals “1.” If it does, then adjust the low-level prox until the value
reads “0.”

Ensure that the material hopper is properly vented. If the vacuum
receiver is leaky, then this will cause the problem. To test this, fill
up the hopper and turn the loader off to prevent leaking.

If this isn’t the problem, then increase the “Out of Material Retry
Limit” found under Feed Algorithm Options (see manual).

Check the Alarm Flags & Feeder Setup to see if the feeder is
configured to give you an alarm.

Clean out the hopper and retest. If this doesn’t fix the problem,
then perform a scale calibration. Also, check to make sure that the
Dump Time is not set extremely low. If all else fails, check the
value set for the Max Empty Weight. This might need to be
increased.

First, check that the displayed actual dispensed weight is accurate.
If this is OK, then check to see if the hopper is properly vented.
To do this, fill hopper and turn off the loader and retest.

882.00207.00 Chapter 6: Troubleshooting 69 of 102

Problem Corrective action

This is caused by the difference in bits not being large enough.

I can’t calibrate the Scale
without an error message.

I can’t calibrate the feeder
without an error message.

Weigh hopper does not empty
completely.

Using the Direct Scale Readout, examine current loadcell bits with
and without the calibration weight. If the bits do not change
significantly, then check for pellets jamming the loadcells and
check the loadcell circuit. You might have a bad loadcell.

Do other feeders calibrate correctly? Is the feeder you’re trying to
calibrate a large gate? If both answers are yes, then lower the
Batch % for Feeder Cal setting under Feed Calibration Options.
This can be observed by looking at the Hopper Weight display.

None of the feeders calibrate? Check the Scale Calibration. If this
is correct, then lower the Batch% for Feeder Cal setting under Feed
Calibration Options for each feeder. This can be observed by
looking at the Hopper Weight display.

Check the dump time setting. It may be set too short.

If this does not correct the problem, clean the weigh hopper and
recheck the scale diagnostics readout. If not showing (0) zero when
empty, re-calibrate the scale.

Verify application is not exceeding blender capacity.

Blender does not make rate.

I have changed the recipe entry
mode, metering order, batch
size, inventory shutdown,
weigh every batch mode, OR
feeder type and alarm flags, but
the change hasn’t taken place.

A feeder always puts too much
material in the batch.

A feeder is retrying more than
2-4 times.

Verify additive percentage is not higher than designed, resulting in
excessive dispense time.

Verify all materials are feeding freely through the metering gates
or augers.

All of these settings are part of the current running recipe. This
makes it easy for the operator to load a stored recipe without
having to reconfigure all of these parameters for the new recipe.
All you have to do is touch “Accept New Recipe” to load these
values into the running recipe.

Check that the Gate Cycle Time is set correctly. If it is then lower
the Initial % of Target to Meter. These are found under Feed
Algorithm Options. Make small adjustments and retest.

Increase the Gate Cycle Time. This is found under Feed
Algorithm Options. Make small adjustments and retest.

Increase the Allowed Underfeed value under Feed Algorithm
Options.

Decrease the Retries before Double Gate Time.

Note: Other service problems or questions can be answered by contacting the Service

Department.

882.00207.00 Chapter 6: Troubleshooting 70 of 102

Chapter 7: Appendix

7-1 Warranty

Unless otherwise specified, this product includes a standard ONE YEAR PARTS WARRANTY.

Warranty Specifications

The manufacturer hereby expressly warrants all equipment manufactured by it to be free from
defects in workmanship and material when used under recommended conditions, as set forth in the
operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY IS
EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTEES,
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR
LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The Company’s
obligation is limited to repair or replace FOB the factory any parts that are returned, prepaid, within
one year of equipment shipment to the original purchaser, and which in the Company’s opinion, are
defective. Any replacement part assumes the unused portion of this warranty.

Warranty Restrictions

This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or
any other work. This warranty does not apply to any equipment which, in the Company’s opinion,
has been subjected to misuse, negligence, or operation in excess of recommended limits, including
freezing or which has been repaired or altered without the Company’s express authorization. If the
serial number has been defaced or removed from the component, the warranty on that component is
void. Defective parts become the property of the warrantor and are to be returned immediately,
without any further use or handling.

Warranty Liabilities

THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM
THE USE OF THIS PRODUCT. Some states do not allow the exclusion or limitation of special,
consequential or incidental damages, so the above limitation may not apply to you. The Company’s
obligation for parts not furnished as components of its manufactured equipment is limited to the
warranty of the manufacturers of said parts. The company neither assumes nor authorizes any other
persons to assume for it any liability in connection with the sale of its equipment not expressed in
this warranty. No person, agent, manufacturer, distributor, dealer, installer or company is authorized
to change, modify or extend the terms of this warranty in any manner whatsoever.

The time within which an action must be commenced to enforce any obligation of the Company’s
arising under this warranty, or under any statute or law of the United States or any state thereof, is
hereby limited to the duration of this warranty. Some states do not permit this limitation, so the
above may not apply to you. This warranty gives you specific legal rights and you may also have
other rights which vary from state to state. For transactions involving the potential applicability of
international law or that of a foreign country, this warranty policy and the procedures hereunder shall
be governed by applicable federal and state law, but not by the United Nations Convention on
Contracts for the Sale of Goods.

Customer Responsibilities

Any sales, use, or other tax incident to the replacement of parts under this warranty is the
responsibility of the purchaser.

882.00207.00 Chapter 7: Appendix 71 of 102

7-2 Technical Specifications

Equipment Specifications

Figure 46: 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 pound 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)

882.00207.00 Chapter 7: Appendix 72 of 102

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Special installation requirements: Clean, dry compressed air 1 cfm @ 60 psi (1.7 m³/hr @

4.14 bar)

9. Allowable voltage fluctuation: +/- 10%

10. Allowable frequency fluctuation: Continuous +/- 1%

Intermittent +/- 2%

11. The addition of an auger feeder (RAM option) for regrind will increase the electrical supply

requirements of a standard blender.

12. Nominal supply voltage: 120/1/60 or 220/1/50/60 (Verify on serial number tag)

13. Earth ground type: TN (system has one point directly earthed through a

protective conductor)

14. Power supply should include a neutral power connection.

15. Over-current protection is supplied in the blender, but additional protection should be

supplied by the user.

16. The plug on the power cord serves as the electrical disconnect device.

17. Unit is not equipped with three-phase motors.

18. N/A

19. Blender is not equipped with local lighting.

20. Functional identification

21. Blender is equipped with a CE mark

22. Blender is supplied with an operating manual in the language of the destination country.

23. Cable support may be required for power cord, depending on final installation.

24. No one is required to be in the interior of the electrical enclosure during the normal

operation of the unit. Only skilled electricians should be inside the enclosure for
maintenance.

25. Doors can be opened with a screwdriver, but no keys are required.

26. Two-hand control is not required or provided.

27. All blenders should be moved around and set in a place with a lift truck or equivalent.

28. There are no frequent repetitive cycles that require manual controlrepetitive functions are

automatic while the blender is operating.

29. An inspection report detailing the functional test is included with the blender.

30. The machine is not equipped with cableless controls.

31. Color-coded (harmonized) power cord is sufficient for proper installation.

882.00207.00 Chapter 7: Appendix 73 of 102

7-3 Drawings and Diagrams

Final Assembly

Figure 47: Typical Final Assembly Parts List

# Description 150 900 2500 4000 6000

Mixer Assembly A0771677 A0771682 A0771683 A0771663 A0771691 A0771692

1

3-Component Hopper Assembly N/A A0771687 A0771664 A0771700
2-Component Hopper Assembly N/A A0771686 A0771665 A0771699

2

Removable Hopper Small CTB01648 N/A
Removable Hopper Large CTB02248 N/A
Slide Gate Assembly – Majors A0771661 A0771660 A0771701

3

Slide Gate Assembly – Minors
Valve Stack Assembly 4-Comp A0770375

4

Valve Stack Assembly 6-Comp
Main Controller A0569133 A0569134

5

Main Display (Not Shown) A0574219

6

Calibration Weight (Not Shown) 822.00334.00 822.00151.00 822.00152.00 A0571769 822.00153.00

7

Hopper Support Straps N/A A0569157 872.00246.00

8

Louvers – Hopper Covers N/A A0567625

9

N/A

N/A

A0771680 A0771661 A0771708

A0770376

882.00207.00 Chapter 7: Appendix 74 of 102

Mixer Sub-Assembly

882.00207.00 Chapter 7: Appendix 75 of 102

Figure 48: Typical Mixer Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

FRAME 872.00093.00 872.00094.00 A0770301 872.00224.00

1

FRAME EXTENSION (NOT SHOWN) N/A 872.00225.00

2

TOP PLATE 872.00095.00 872.00096.00 A0770300 872.00226.00

3

MOUNTING BRACKET – MIXER MOTOR 872.00097.00 872.00098.00 A0770316

4

MIX CHAMBER BACK PLATE 872.00099.00 872.00100.00 A0770333 872.00227.00

5

COUPLING – AGITATOR DRIVE 832.00010.00 A0770318

6

AGITATOR – MIXING 872.00101.00 872.00102.00 A0574115 872.00228.00

7

DRAWER SUPPORT 832.00011.00 A0770320 832.00034.00

8

BUSHING – AGITATOR 832.00012.00 A0770319 21063

9

LOADCELL (TWO)

10

MOUNTING BRACKET – WEIGH

11

HOPPPER
COVER GUARD – LOADCELL A0770322

12

WEIGH HOPPER 872.00103.00 872.00104.00 A0770312 872.00229.00 872.00230.00

13

STOP RAIL – MIXER DRAWER 872.00105.00 872.00106.00 A0770314 872.00231.00

14

MIXER DRAWER 872.00107.00 872.00108.00 A0770315 872.00232.00

15

ACCESS DOOR – MIXER 832.00013.00 832.00014.00 A0770303 832.00035.00 832.00036.00

16

DOOR CLIPS 09990

17

SAFETY COVER – MIXER FRONT (NOT

18

SHOWN)
DOOR LATCH 35454

19

SUPPORT BRACE – MIXER DOOR N/A 872.00110.00 A0770332 872.00233.00

20

SAFETY COVER – MIXER BACK 872.00111.00 872.00112.00 A0770302 872.00234.00

21

MOUNTING BRACKET – CONTROL

22

PANEL (NOT SHOWN)
PROXIMITY SENSOR – MIXER HIGH-

23

LEVEL
E-STOP SAFETY DISCONNECT SWITCH 64269

24

SAFETY DISCONNECT SWITCH –

25

MIXER DOOR
GEAR MOTOR 720.00001.00 720.00002.00

26

FLOW VALVE 1/4" TUBING A0770190

27

724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00

A0770313

872.00109.00 N/A

872.00124.00 N/A

A0556548

A0567124

882.00207.00 Chapter 7: Appendix 76 of 102

Hopper Sub-Assembly

Figure 49: Typical Hopper Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

3-COMPONENT HOPPER 872.00118.00 A0569131 872.00240.00

1

2-COMPONENT HOPPER 872.00119.00 A0770299 872.00241.00
LEXAN DOOR A0770286

3

DOOR LATCH A0770076

4

3.5” SIGHT GLASS A0569154 N/A

5

4.5” SIGHT GLASS N/A A0770323

6

(OPTIONAL) 2” DRAIN W/ MANUAL
GATE (NOT SHOWN)

7

(OPTIONAL) 3” DRAIN W/ MANUAL
GATE (NOT SHOWN)
(OPTIONAL) BRACKET - LOW-LEVEL

8

SENSOR (NOT SHOWN)
(OPTIONAL) PROXIMITY SENSOR LOW-

9

LEVEL (NOT SHOWN)

A0569162 N/A

N/A A0569163

A0569155

A0556548

882.00207.00 Chapter 7: Appendix 77 of 102

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

Figure 50: Typical R.A.M. Hopper Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

THROAT 07822-1

1

CLAMP A0548808

2

FEEDER TUBE # 872.00426.00 #

3

DRAIN HOUSING 08806A-HYD

4

DRAIN SLIDE GATE 08806B

5

MOTOR MOUNT BRACKET 08451

6

SEAL – AUGER - TEFLON 55372

7

MOTOR - AUGER 720.00004.00

8

AUGER # 872.00421.00 #

9

HOPPER 2.0 CU.FT. 872.00417.00 N/A

10

HOPPER 7.0 CU.FT. N/A 872.00418.00
DOOR A0770286

11

LATCH A0770076

12

SAFETY INTERLOCK SWITCH A0567124

13

BRACKET – SAFETY SWITCH 872.00431.00

14

SIGHTGLASS 4.5” A0770323

15

MOTOR – AGITATOR 51489

16

AGITATOR 10637

17

SEAL – AGITATOR - RUBBER 15286

18

RECEPTACLE – 3-PIN FEMALE 63119

19

CORD 3-PIN MALE 6 FT LONG 55196

20

STEADY STATE RELAY – 10 AMP 729.00183.00

21

GLASS FUSE – 3.0 AMP (115V UNIT) A0542207

22

GLASS FUSE – 1.5 AMP (230V UNIT) A0542200

882.00207.00 Chapter 7: Appendix 78 of 102

Hopper Additive Feeder Sub-Assembly (Optional)

Figure 51: Typical Additive Feeder Hopper Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

THROAT A0541201

1

MOTOR MOUNT BRACKET A0541229

2

MOTOR – AUGER 51450G

3

THROAT ADAPTER – 2” RISER 872.00537.00 N/A

4

HOPPER 1.0 CU.FT. A0541207 N/A

5

HOPPER 2.0 CU.FT. N/A A0541208
SIGHTGLASS – AF A0541206

6

COVER PLATE – HOPPER CLEANOUT A0541215

7

COVER PLATE – SAMPLE PORT A0541216

8

TRANSFER TUBE – 1” AUGER A0541211 #

9

AUGER ASSEMBLY – 1” AUGER A0541294 #

10

COUPLING – MOTOR/AUGER A0541282

11

PIN – MOTOR MOUNT (NOT SHOWN) A0541277

12

RECEPTACLE – 3-PIN FEMALE

13

(NOT SHOWN)
CORD 3-PIN MALE 6 FT LONG

14

(NOT SHOWN)
STEADY STATE RELAY – 10 AMP

15

(NOT SHOWN)
GLASS FUSE – 3.0 AMP (115V UNIT)
(NOT SHOWN)

16

GLASS FUSE – 1.5 AMP (230V UNIT)
(NOT SHOWN)

63119

55196

729.00183.00

A0542207

A0542200

882.00207.00 Chapter 7: Appendix 79 of 102

Weigh Hopper Sub-Assembly

Figure 52: Typical Weigh Hopper Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

WEIGH HOPPER 872.00103.00 872.00104.00 A0770312 872.00229.00 872.00230.00

1

AIR CYLINDER 245.00003.00 A0770248

2

CLEVIS – AIR

3

CYLINDER
FITTING – AIR

4

TUBING
AIR TUBING (NOT

5

SHOWN)

35460 35449

35086K 35085K

35300K

882.00207.00 Chapter 7: Appendix 80 of 102

Slide Gate Sub-Assembly

Figure 53: Typical Slidegate Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

HOUSING (DOUBLE DIAMOND) (#1-4) 872.00114.00 A0770304 872.00524.00
HOUSING (SQUARE / DIAMOND) (#1-4) A0770308 N/A 1
HOUSING (DOUBLE DIAMOND) (#5-6) 872.00113.00 A0770308
GATE – DIAMOND (#1-4) A0770309 A0770305 872.00237.00

2

GATE – SQUARE (#1-4) (NOT SHOWN) 872.00116.00 N/A 872.00236.00
GATE – DIAMOND (#5-6) 872.00115.00 A0770309 872.00237.00
GUIDE ROD (#1-4) A0770311 A0770307

3

GUIDE ROD (#5-6) 832.00015.00 A0770311
AIR CYLINDER (#1-4) 35448

4

AIR CYLINDER (#5-6) 245.00006.00
CLEVIS – AIR CYLINDER (#1-4) 35449

5

CLEVIS – AIR CYLINDER (#5-6) 35460
FITTINGS – AIR CYLINDER A0770136

6

STROKE LIMITER (#1-4) A0770310 A0770306

7

STROKE LIMITER (#5-6) 82.00117.00 A0770310
QUICK RELIEF VALVES (NOT SHOWN) N/A 245.00024.00

8

35448 245.00016.00

35449 A0770296

872.00235.00

832.00037.00

872.00238.00

882.00207.00 Chapter 7: Appendix 81 of 102

Knife Gate Sub-Assembly HD (Optional)

Figure 54: Typical Knife Gate (below mixer) Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

BASE FRAME 07990

1

MOLDED THROAT 53413

2

SPACER PLATE 08286

3

FLANGE ADAPTER 08292

4

KNIFE BLADE 10644

5

MOUNTING BRACKET – AIR CYLINDER 33088

6

AIR CYLINDER 33091

7

- -

8

MOUNTING NUT – AIR CYLINDER A0553239

9

CLEVIS – AIR CYLINDER 33090

10

BUSHING 1/4 - 1/8 NPT 35014

11

ELBOW 1/8 NPT 35118

12

SOLENOID 4-WAY 24VDC 33128

13

FITTING – 1/8 NPT X 1/4 TUBE 35086K

14

MUFFLER 1/8 NPT FLUSH 35157

15

FITTING – 1/4 NPT X 1/4 TUBE 35154

16

SAFETY SHIELD A0770362 A0770363 A0770364 A0770365

17

STROKE LIMITER PIPE (NOT SHOWN) 07990B

18

882.00207.00 Chapter 7: Appendix 82 of 102

Knife Gate Sub-Assembly RD (Optional)

Figure 55: Typical Knife Gate (floor stand) Assembly Parts List

# DESCRIPTION 500 900 2500 4000 6000

HOUSING FRAME 872.00297.00

1

GUARD SAFETY COVER 872.00236.00

2

ROD GUIDE 832.00049.00

3

GATE – SLIDE BLADE 872.00236.00

4

AIR CYLINDER 245.00016.00

5

CLEVIS – AIR CYLINDER A0770296

6

NUT – LOCKING A0533826

7

FITTING ELBOW 1/8 NPT X 1/4 TUBE 35086K

8

NIPPLE 1/8 NPT A0015494

9

SOLENOID 4-WAY 24VDC 33128

10

FITTING STRAIGHT 1/8 NPT X 1/4 TUBE 35085K

11

FITTING MUFFLER STONE 1/8 NPT 35157

12

882.00207.00 Chapter 7: Appendix 83 of 102

Control Panel Layout

Figure 56: Typical Mitsubishi Controller Main Parts List

# Description 150 500 900 2500 4000 6000

Mitsubishi PLC FX2N-32MR A0569702

1

Mitsubishi PLC EEPROM A0569703

2

24 vdc Power Supply A0563932

3

Calex Module – Load Cell Amplifier 724.00117.00

4

Alarm Light Yellow Strobe 24 vdc A0565889

5

Alarm Horn 95db 24vdc A0542574

6

Glass Fuse – 1.5 amp (115v unit) A0542200

5

Glass Fuse – 1.0 amp (230v unit) A0540997
Glass Fuse – 3.0 amp (115v unit) A0542207

6

Glass Fuse – 1.5 amp (230v unit) A0542200
Motor Contactor A0573025 (9 amp) A0573026 (12 amp)

7

Motor Overload – MCP (115v unit) A0558252 (1.6-2.5 amp) A0558255 (6.3-10.0 amp)

8

Motor Overload – MCP (230v unit) A0558251 (1.0-1.6 amp) A0558254 (4.0-6.3 amp)
Light Bulb – Power Switch (115v unit) A0544076

9

Light Bulb – Power Switch (230v unit) A0567108
Light Bulb – Safety Active 24vdc A0565884

10

Alarm Relay A0567058

11

Figure 57: Typical Mitsubishi Display Main Parts List

# Description 150 500 900 2500 4000 6000

Mitsubishi Pendant Touchscreen Display A0569706

1

Display – 32 ft Connection Cable A0569705

2

882.00207.00 Chapter 7: Appendix 84 of 102

7-4 Spare Parts Kits

A

A

A

A

A

A

A

A

A

A

A

A

Figure 58: Blender Spare Parts Listing

Model 150 500 900 2500 4000 6000

KIT "A" (Consumables) A0574120

Load Cell Assembly (without plug) # 724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00
Mixer High Level Sensor #
(5) Fuses, 1.5 Amp
(5) Fuses, 3.0 Amp

KIT "B" (Minimal Dow ntime) A0574121

All "A" Kit Parts A0574120 A0574134 A0574137 A0574125 A0574140 A0574143
Slide Gate Air Cylinder - Majors #
Slide Gate Air Cylinder - Minors # 35448
Weigh Hopper Air Cylinder #
Mixer Motor Contactor
Power Supply, 24vdc
Mixer Door Safety Switch #

KIT "C" (24/7 Operation, or International) A0574122

All "A" and "B" Kit Parts A0574121 A0574135 A0574138 A0574126 A0574141 A0574144
Second Load Cell Assembly (without plug) 724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00
Mixer Motor Protector (overload)
Calex Module

Other Recomm ended Parts 150 500 900 2500 4000 6000

Mixer Gear Motor # 720.00002.00
Mixer Agitator # 872.00101.00 872.00102.00 872.00225.00
Mixer Coupling N/A
Weigh Hopper Assembly # A0771684 A0771685 A0771662 A0771704 A0771705
Valve Stack Assembly N/A
MIT Pendant Operator Touch Screen
MIT PLC CPU
MIT PLC EEPROM

One of each of these parts is recommended if you have MULTIPLE blenders and rely on long term, continous operation.

0574134

0574135

245.00006.00 245.00016.00

245.00003.00 A0770248

A0573025 A0573026

0574136

A0558252 A0558255

720.00001.00 720.00002.00

832.00010.00 832.00030.00

A0770132 (4-Component) -or- A0770144 (6-Component)

0574137

(5) A0542200
(5) A0542207

0574138

35448 245.00016.00

A0563932

0574139

724.00117.00

A0569706
A0569702
A0569703

0574125 A0574140

A0556548

0574126 A0574141

A0567124 + A0567125

0574127 A0574142

872.00228.00

0574143

0574144

0574145

882.00207.00 Chapter 7: Appendix 85 of 102

7-5 Addendum (Service Supervisor Information)

This section of the manual should not be used by untrained personnel – blender controller and/or
program can be compromised!

WARNING! Hidden, programmable features and hidden menu pages should not be made

available to floor operators or inexperienced plant personnel. These pages include
the Service Supervisor Information addendum located in this section.
Unauthorized changes to these factory settings by inexperienced operators may
prevent the unit from operating properly, and may void part or all of the warranty.

After all selections are made, keep pressing the “Done” key until the unit returns to the Recipe
menu.

Call the Service Department for assistance or for further explanation of these or any other
programmable features, which may or may not be shown in this manual. Information included in
this manual is subject to change without notice.

Passwords

• User Password “5413”

• Maintenance Password “3145348”

Caution! Maintenance password should only be supplied to qualified personnel! The

program can be compromised.

Programmable Settings

The Slide Gate/Auger blender software program has been designed to allow some customizing to
achieve certain desired operating parameters. The following is a listing of the selections that are
“field” programmable, followed by the procedure for doing so.

This menu is accessed by pressing the manufacturer’s icon when in the “Setup” Directory Screen
menu.

Touch this icon and
enter in the Service
Password to access the
Engineering Only
Directory

Enter the long password “3145348” and press “Enter”. The factory setup section displays the
“Engineering only” screen. The screen similar to that shown below should be displayed and use the
keystrokes described herein to change or toggle the parameters.

Typical Operator Setup Screen

882.00207.00 Chapter 7: Appendix 86 of 102

Factory Setup Menu

Metering Test Screen

This screen is useful in both R & D and development purposes when testing the metering
performance of each feeder. The user can perform a “Single Meter by Weight” to evaluate the
mechanical standard deviation of the gate or auger. This test meters for the calculated time based off
the target weight entered on this screen. The blender does not retry or adjust the time of the meter to
reach the target, but instead always meters for the same amount of time as long as the target weight
has not been changed. This allows you to open the gate for several feeds using the same amount of
time. You can then record the Dispensed Grams and plot the standard deviation of the gate. The
other purpose of this screen is to verify that the dispensed weight displayed is correct. You can
perform a meter and then pull the weigh hopper to weigh the material on a gram scale. The value on
the screen should match the measurement on the gram scale. If it does not, then either the weigh
hopper is not balanced correctly or the scale calibration is not correct. Refer to the Troubleshooting
Section of this manual for additional details.

Typical Engineering Only Setup Screen

Go back to
Setup
Directory

Typical Metering Test Screen

Select a Feeder

Target Weight

Meter Data

Stop the Meter

Change Method

Go back to
Engineering
Only Directory

Advanced Weight Options Screen

This screen allows you to modify the weight filter, adjust the mechanical time to settle the weigh
hopper after dumping, adjust the mechanical time to settle after a feeder has introduced material into
the weigh hopper, adjust the Maximum Empty Weight of the hopper, and to enable the batch weight
data to be dumped to a printer every batch for diagnostic purposes. The data that is dumped to a
printer is the same data shown on the Recipe Screen. No averaging is done with the data shown to
the Customer. Targets vs. Actual are actually what is in the batch without any “smoke and mirrors.”

The weight filter is the specialized filter algorithm that smoothes erroneous load cell readings. The
signal will be filtered more if this value is increased and less if decreased. This setting should not be
modified except by the developer except under unusual circumstances.

882.00207.00 Chapter 7: Appendix 87 of 102

r

Typical Advanced Weight Options Screen

Weight Filter

Weight/Sec.

Filte

Adjust the limit

for “Hopper Over

Max Weight”

Adjust Settle

Go back to

Engineering Only

Directory

Feed Algorithm Options Screen

This screen allows the user to configure how the blender metering algorithm works. The user can
adjust the Initial percentage of Target to Meter, the Allowed Underfeed value, the number of retries
before Double Gate Time, the allowed Weight/Sec Drop, and the Out of Material retry limit.

Typical Feed Algorithm Options Screen

Go back to

Engineering Only

Directory

Feed Calibration Options Screen

This screen allows you to perform the feeder calibrations for each feeder (in weight per second).
This is useful when the feed calibration is giving you an error message (most commonly caused by
overfilling the hopper during the calibration). Select a feeder and then follow instructions. An error
is shown if the current feeder calibration feed time was too short, the feed time was too long, or if
the hopper weight exceeded 110% of the set batch weight. In the case that the feeder exceeded
110% (maximum hopper weight) due to a high rate hopper then the “Batch % for Feeder Cal” setting
might be set too high. Consult the manufacturer if this problem arises. The current feeder
calibration values are also shown on this page. It is not necessary to perform feeder calibrations.

The blender will automatically learn these values during the batch.

Typical Feed Calibration Options Screen

Go back to

Engineering Only

Directory.

882.00207.00 Chapter 7: Appendix 88 of 102

Mechanical Options Screen

This screen allows the user to change the number of hoppers, the predetermined gate cycle time, and
the mixer bump time for detecting high level.

The gate cycle time has been measured and set at the factory, but might need to be adjusted if we
change the mechanical design of the gate, solenoids, and air cylinders. This setting will vary
depending on whether you are using a gate or an auger.

Typical Mechanical Options Screen

Go back to

Engineering

Only Directory

Feeder Setup

This screen allows you to modify the type of each feeder. In most cases, the user will want to keep
regrind on hopper 3 because that blender has been specifically designed to handle the regrind. These
settings should only be modified under special circumstances.

If the blender is configured in “EZ Mode” then one hopper must be configured for Regrind and only
one hopper must be configured for Virgin material. If this is incorrect, a message will be given on
the Recipe Screen.

Typical Feeder Setup Screen

Go back to

Engineering Only

Directory.

882.00207.00 Chapter 7: Appendix 89 of 102

Customer Setup Menu

Units

This screen allows the user to change the blender’s unit of measurement. The entire blender can be
configured in either Kgs. or Lbs., while the Target vs. Actual data can be configured for either
regardless of the blender’s units.

Typical Units Screen

Change Target vs.
Actual Units

Change
Blender’s
Units

Go back to
Setup
Directory

Network Setup

This screen allows the blender to be configured for use with the Ethernet Option. The blender will
automatically configure the Ethernet module’s IP Address and Subnet Mask if the configurator is
enabled. Whenever you modify the IP Address or subnet, you either need to reboot the PLC.

Typical Ethernet Setup Screen

Enable or
Disable the
Ethernet

Go back to Setup
Directory

882.00207.00 Chapter 7: Appendix 90 of 102

Alarm Setup

This screen allows the user to configure the feeder type for each feeder; configure whether a feeder
will retry during the metering of a batch, and enable or disable the “Out of Material” alarm for any
feeder. If a hopper is set to “No Retry” then the blender will continue to meter the rest of the batch
even if this hopper runs out of material. No “Out of Material” alarm will be given regardless of how
the alarm is configured unless the user has purchased and wired in the low level proximity switches
in each hopper. To configure each hopper, perform the following steps:

1. Select a feeder by touching the “Select Feeder” box.

2. The current settings for that hopper will be shown.

3. Make the necessary adjustments and select a new feeder to configure if desired.

4. Press “Done” to exit.

Typical Alarm Flags & Feeder Setup Screen

Select a Feeder to
Configure

Change the Alarm
Silence Delay

Alarm Log

This screen shows the last 100 stored alarms. The log can be viewed, printed and cleared.

Clear Alarm
Log

Print Alarm
Log

Typical Alarm Log Screen

Scroll Through
Alarm Log

Enable or Disable
Retries

Enable or Disable
Alarms

Go back to Setup
Directory

Alarm Log

Go back to
Setup
Directory

882.00207.00 Chapter 7: Appendix 91 of 102

Factory Default Setup Parameters

A

A

y

A

y

A

l

y

s

d

l

l

l

l

l

l

l

l

s

d

Model Number 150

ALL WEIGHT VALUES RECORDED IN POUNDS

RECIPE FORMAT

Recipe Entry Mode
Metering Order
Batch Size (lbs)
Inventory Shutdown
Batch Ready Mode

utoStart Mode

Weighing mode

REPORT SETUP

Blender Number

uto Print Inventor
uto Clear Inventor
uto Print/Clear Interva

Start Hour

SCALE CALIBRATION

PERFORM A SCALE CALIBRATION ON ALL MANUFACTURED UNITS

DIRECT SCALE READOUT

LOG THESE VALUES AFTER THE SCALE CALIBRATION WITH THE ORDER INFORMATION

FEEDER CALIBRATION

Hop1 wt/sec (lbs)
Hop2 wt/sec (lbs)
Hop3 wt/sec (with square gate) (lbs)
Hop4 wt/sec (lbs)
Hop5 wt/sec (lbs)
Hop6 wt/sec (lbs)
Hop7 wt/sec (lbs)
Hop8 wt/sec (lbs)

"Feeder Calibration wt/sec" values assume stroke limiters installed

MIXER AND DUMP SETUP

Mixing Time
Remix Time
Dump Time
Dump Dela
Dump Cycle
Mixer Dump Time (w/o knifegate set to 0)
Continuous/Timed Mixing

USER PASSWORD

User Passwor
Maintenance Password

ALARM SETUP

Hop1 Continue/Stop on Out of Material
Hop2 Continue/Stop on Out of Material
Hop3 Continue/Stop on Out of Material
Hop4 Continue/Stop on Out of Material
Hop5 Continue/Stop on Out of Material
Hop6 Continue/Stop on Out of Material
Hop7 Continue/Stop on Out of Material
Hop8 Continue/Stop on Out of Material
Hop1 Alarm/No Alarm on Out of Materia
Hop2 Alarm/No Alarm on Out of Materia
Hop3 Alarm/No Alarm on Out of Materia
Hop4 Alarm/No Alarm on Out of Materia
Hop5 Alarm/No Alarm on Out of Materia
Hop6 Alarm/No Alarm on Out of Materia
Hop7 Alarm/No Alarm on Out of Materia
Hop8 Alarm/No Alarm on Out of Materia

NETWORK SETUP

Ethernet Configurator
IP Addres
Subnet Mask

ADVANCED WEIGHT OPTIONS

Weight Filter
Max Tare Offset (lbs)
Wt/Sec Filter
% Above batch size for max weight
Time to settle hopper after batch dumpe
Simulator
Weight Data Printing

(DIVIDE BY 2.20462 FOR KILOGRAMS)

PERCENTAGE

in hoppers #2 & #4 & #5 thru #8

500 900 2500 4000 6000

"EZ" MODE / "QUICK SET" MODE

2.0 4.0 8.0 25.0 35.0 45.0

0.25 1.50

0.25 1.50

1

1

46

12345678

0
ENABLED
ENABLED

EVERY BATCH

1

DISABLED
DISABLED

8

0

1.00

2.00

0.25

0.25

0.25

0.25

0.25

4
0

2

0

2

TIMED

5413

3145348

STOP
STOP
STOP
STOP
STOP
STOP
STOP

STOP
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM

ENABLED

192.168.0.10

255.255.255.0

5
1
1

25

5

Simulator off

Don't Print Weight Data

10.00

3.000.25

10.00

3.00

3.00

3.00

1.00

1.00

4

1

882.00207.00 Chapter 7: Appendix 92 of 102

Model Number 150

y

ALL WEIGHT VALUES RECORDED IN POUNDS

FEED ALGORITHM OPTIONS

Hop1 Initial % of Target
Hop2 Initial % of Target
Hop3 Initial % of Target
Hop4 Initial % of Target
Hop5 Initial % of Target
Hop6 Initial % of Target
Hop7 Initial % of Target
Hop8 Initial % of Target
Hop1 Allowed Underfeed (lbs)
Hop2 Allowed Underfeed (lbs)
Hop3 Allowed Underfeed (lbs)
Hop4 Allowed Underfeed (lbs)
Hop5 Allowed Underfeed (lbs)
Hop6 Allowed Underfeed (lbs)
Hop7 Allowed Underfeed (lbs)
Hop8 Allowed Underfeed (lbs)
Double Gate Threshold
Out of Material Retry limit before alarm
Batches for process rate
Process Rate Filter

"Initial Target %" and "Allowed Underfeed" values assume stroke limiters installed

FEED CAL OPTIONS

Hop1 Batch % for feeder cal
Hop2 Batch % for feeder cal
Hop3 Batch % for feeder cal
Hop4 Batch % for feeder cal
Hop5 Batch % for feeder cal
Hop6 Batch % for feeder cal
Hop7 Batch % for feeder cal
Hop8 Batch % for feeder cal

MECHANICAL OPTIONS

Hop1 Gate Cycle Time
Hop2 Gate Cycle Time
Hop3 Gate Cycle Time
Hop4 Gate Cycle Time
Hop5 Gate Cycle Time
Hop6 Gate Cycle Time
Hop7 Gate Cycle Time
Hop8 Gate Cycle Time
Hop1 Settle Time
Hop2 Settle Time
Hop3 Settle Time
Hop4 Settle Time
Hop5 Settle Time
Hop6 Settle Time
Hop7 Settle Time
Hop8 Settle Time
Loadcells
Mixer Bump Time to Detect high level
Number of Hoppers for displa

FEEDER SETUP

Hop1 Feeder Type
Hop2 Feeder Type
Hop3 Feeder Type
Hop4 Feeder Type
Hop5 Feeder Type
Hop6 Feeder Type
Hop7 Feeder Type
Hop8 Feeder Type

LOADCELL CALEX MODULE DIPSWITCH SETTINGS

Switches set to "ON" position

SPECIAL NOTES

2 - Component Blenders with R.A.M. - Consult Engineering

(DIVIDE BY 2.20462 FOR KILOGRAMS)

0.001

0.001

0.001

0.001

0.001

0.001

0.001

0.001

in hoppers #2 & #4 & #5 thru #8

0.01

0.01

0.01 0.05

0.01

0.01

0.01

0.01

0.01

1 Loadcell

"Gate Cycle Time" values assume stroke limiters installed

in hoppers #2 & #4 & #5 thru #8

500 900 2500 4000 6000

99

99
99
99
99
99

3
3
3
3
3
3
3
3

99

98

99

98
98
98
98
98

0.015

0.004 0.01

0.015

0.004

0.004

0.004

0.004

0.004

5
10
10

3

25

10
10
10

10
10
10
10

0.05

0.05

0.10 0.10

0.05

0.05

0.05

0.05

0.05
23
2
2
2
2

4
4

2 Loadcells

0.25

SEE ORDER

VIRGIN
ADDITIVE
REGRIND
ADDITIVE
ADDITIVE
ADDITIVE
ADDITIVE
ADDITIVE

#1 & #2

100

100

0.03

0.03

0.01

0.01

0.01

0.01

0.01

25
25
25

0.10

3
3
3
3
32

882.00207.00 Chapter 7: Appendix 93 of 102

7-6 Mitsubishi Communications Manual

The Mitsubishi blender uses a FX-2N processor that communicates with the outside world using
MELSEC FX protocol over Ethernet hardware. It’s Ethernet speed is 10 Mbits/second. The blender
must be purchased from ACS with the Ethernet option. If this was not done at the time of purchase
it can be added afterwards by consulting the factory. The blender has a programmable IP address
and subnet mask that can be programmed from software that is provided by DIGI for the Ethernet
module (refer to their manual).

Ethernet is the standard that we support, but Mitsubishi also supports Profibus and MELSEC Serial
communications. Refer to Mitsubishi for parts and information.

The communications port settings on the PLC are: 19,200 baud; 8 data bits; no parity;1 stop bit;
software flow control.

The communications must also be enabled. From the main screen touch the “next” button to go to
the “inventory” page. Touch “Log in” and type in “5413”. Then touch the “ACS logo” and this will
take you to setup. Touch the “Network Setup” button and ensure that communications is enabled. If
it wasn’t then you’ll need to change it and then reboot the PLC for it to take effect. The Ethernet
module takes about 45 seconds to regain communications upon boot.

Note: Items marked (r) are read only and items marked (rw) are read/write.

Below are the items that can be accessed for the blender:

GENERAL BLENDER INFO

1 (R) plc_version,D1942,SHORT VALUE (xx.x)

2 (R) number_of_hoppers,D1702,SHORT VALUE (number of hoppers on the blender)

3 (R) maximum_blender_throughput,D1056,LONG VALUE(maximum rate blender can achieve)

4 (R) average_batch_time, D1938,SHORT VALUE (average amount of time it takes to finish the
batch)

5 (R) average_process_rate,D1334,LONG VALUE (average rate at which the process is consuming
blended material)

BLENDER STARTING AND STOPPING

1 (R) blender_started,M500

2 (RW) blender_start_request,M540 (toggle this to start or stop the blender, blender will switch it’s
current status, you must also reset this bit after completion)

3 (RW) abort_batch_request,M508 (toggle this to immediately stop the blender even if the batch is
incomplete, you must also reset this bit after completion)

882.00207.00 Chapter 7: Appendix 94 of 102

BLENDER ALARMS

1 (R) alarm_number,D1876 (see below for description)

2 (R) hop1_out_of_material,M561

3 (R) hop2_out_of_material,M562

4 (R) hop3_out_of_material, M563

5 (R) hop4_out_of_material, M564

6 (R) hop5_out_of_material, M565

7 (R) hop6_out_of_material, M566

8 (R) hopper_over_max_alarm,M570

9 (R) empty_weight_exceeded,M571

10 (R) inventory_cleared,M572 (use this bit to record when an operator cleared the inventory at the blender)

11 (R) power_interruption,M576 (this alarm engages when the PLC loses power during a batch)

12 (R) hop1_low_level,M618 (this alarm is only available if the hoppers have low level prox switches)

13 (R) hop2_low_level,M619 (this alarm is only available if the hoppers have low level prox switches)

14 (R) hop3_low_level,M620 (this alarm is only available if the hoppers have low level prox switches)

15 (R) hop4_low_level,M621 (this alarm is only available if the hoppers have low level prox switches)

16 (R) hop5_low_level,M622 (this alarm is only available if the hoppers have low level prox switches)

17 (R) hop6_low_level,M623 (this alarm is only available if the hoppers have low level prox switches)

18 (R) plc_battery_low,s:M743

882.00207.00 Chapter 7: Appendix 95 of 102

INVENTORY INFO

1 (RW) clear_inventory,M503 (toggle this to clear all inventory, you must also reset this bit after completion)

2 (RW) batch_counter,D1336,LONG VALUE (number of batches made)

3 (R) hop1_inventory,D1274,LONG VALUE (this is the whole portion of the inventory)

4 (R) hop2_inventory,D1276,LONG VALUE (this is the whole portion of the inventory)

5 (R) hop3_inventory,D1278,LONG VALUE (this is the whole portion of the inventory)

6 (R) hop4_inventory,D1280,LONG VALUE (this is the whole portion of the inventory)

7 (R) hop5_inventory,D1282,LONG VALUE (this is the whole portion of the inventory)

8 (R) hop6_inventory,D1284,LONG VALUE (this is the whole portion of the inventory)

9 (R)batch_inventory,D1344,LONG VALUE (this is the whole portion of the inventory)

10 (R) hop1_fractional_inventory,D1306,LONG VALUE (this is the fractional part of the inventory .xxx)

11 (R) hop2_fractional_inventory,D1308,LONG VALUE (this is the fractional part of the inventory .xxx)

12 (R) hop3_fractional_inventory,D1310,LONG VALUE (this is the fractional part of the inventory .xxx)

13 (R) hop4_fractional_inventory,D1312,LONG VALUE (this is the fractional part of the inventory .xxx)

14 (R) hop5_fractional_inventory,D1314,LONG VALUE (this is the fractional part of the inventory .xxx)

15 (R) hop6_fractional_inventory,D1316,LONG VALUE (this is the fractional part of the inventory .xxx)

16 (R) batch_inventory_decimal_part,D1352,LONG VALUE (this is the fractional part of the inventory .xxx)

882.00207.00 Chapter 7: Appendix 96 of 102

RECIPE INFO (THIS IS WHERE YOU RIGHT THE NEW RECIPE TO)

1 (RW) temp_recipe_entry_mode,D1706, SHORT VALUE (0=percentage mode, 1=parts mode, 2=EZ mode)

2 (R) temp_batch_size_recipe_value,D1234,LONG VALUE (xxx.x lbs or kgs)

3 (RW) pv1_hop1_temp_recipe_value,D1110,LONG VALUE (xxx.xx, write your new recipe here)

4 (RW) pv1_hop2_temp_recipe_value,D1112,LONG VALUE (xxx.xx, write your new recipe here)

5 (RW) pv1_hop3_temp_recipe_value,D1114,LONG VALUE (xxx.xx, write your new recipe here)

6 (RW) pv1_hop4_temp_recipe_value,D1116,LONG VALUE (xxx.xx, write your new recipe here)

7 (RW) pv1_hop5_temp_recipe_value,D1118,LONG VALUE (xxx.xx, write your new recipe here)

8 (RW) pv1_hop6_temp_recipe_value,D1120,LONG VALUE (xxx.xx, write your new recipe here)

9 (R) pv1_recipe_error_message,D1690, SHORT VALUE(1=total not 100%, 2=feeder type error, 3=entry
over 100%)

10 (R) pv1_accept_recipe_enabled,M504 (this bit goes high if a new recipe is valid)

11 (RW) pv1_accept_recipe_requested,M506 (toggle this bit to accept a valid recipe, you must also reset this
bit after completion)

CURRENT RECIPE INFO (THIS IS THE RECIPE THAT IS CURRENTLY BEING MADE)

1 (R) current_recipe_entry_mode,D1688,SHORT VALUE (0=percentage mode, 1=parts mode, 2=EZ mode)

2 (R) current_batch_size_recipe_value,D1168,LONG VALUE (xxx.x lbs or kgs)

3 (R) current_hop1_recipe_value,D1150,LONG VALUE (xxx.xx, recipe value for running recipe)

4 (R) current_hop2_recipe_value,D1152,LONG VALUE (xxx.xx, recipe value for running recipe)

5 (R) current_hop3_recipe_value,D1154,LONG VALUE (xxx.xx, recipe value for running recipe)

6 (R) current_hop4_recipe_value,D1156,LONG VALUE (xxx.xx, recipe value for running recipe)

7 (R) current_hop5_recipe_value,D1158,LONG VALUE (xxx.xx, recipe value for running recipe)

8 (R) current_hop6_recipe_value,D1160,LONG VALUE (xxx.xx, recipe value for running recipe)

HIDDEN RECIPE INFO (THIS IS THE RAW RECIPE THAT WILL BE LOADED AT NEXT
BATCH)

1 (R) recipe_entry_mode,D1686,SHORT VALUE (0=percentage mode, 1=parts mode, 2=EZ mode)

2 (R) batch_size_recipe_value,D1146,LONG VALUE (xxx.x lbs or kgs)

3 (R) hop1_recipe_value,D1128,LONG VALUE (xxx.xx, recipe value for running recipe)

4 (R) hop2_recipe_value,D1130,LONG VALUE (xxx.xx, recipe value for running recipe)

5 (R) hop3_recipe_value,D1132,LONG VALUE (xxx.xx, recipe value for running recipe)

6 (R) hop4_recipe_value,D1134,LONG VALUE (xxx.xx, recipe value for running recipe)

7 (R) hop5_recipe_value,D1136,LONG VALUE (xxx.xx, recipe value for running recipe)

8 (R) hop6_recipe_value,D1138,LONG VALUE (xxx.xx, recipe value for running recipe)

9 (R) recipe_target_total,D1144,LONG VALUE (xxx.xx, the is the total of hop1-hop6 from above, you must
manually add this if you chose to skip the blenders error checking, you must also ensure that you are in the
correct recipe_entry_mode! SEE BELOW FOR DETAILS)

882.00207.00 Chapter 7: Appendix 97 of 102

RECIPE BOOK MANIPULATION

1 (RW) recipe_book_number, D2088, SHORT VALUE (select stored recipe number here)

2 (RW) load_recipe_book_recipe, M554 (toggle this to load the selected recipe, then toggle the accept recipe
bit)

TARGETS VS. ACTUAL WEIGHT INFO

1 (R) print_data_now,M527 (read this tag and when it goes high record the actual weights)

2 (R) hop1_displayed_target_weight,D1078,LONG VALUE (target meter weight for batch, xxx.xxx)

3 (R) hop2_displayed_target_weight,D1080,LONG VALUE (target meter weight for batch, xxx.xxx)

4 (R) hop3_displayed_target_weight,D1082,LONG VALUE (target meter weight for batch, xxx.xxx)

5 (R) hop4_displayed_target_weight,D1084,LONG VALUE (target meter weight for batch, xxx.xxx)

6 (R) hop5_displayed_target_weight,D1086,LONG VALUE (target meter weight for batch, xxx.xxx)

7 (R) hop6_displayed_target_weight,D1088,LONG VALUE (target meter weight for batch, xxx.xxx)

8 (R) hop1_displayed_actual_weight,D1094,LONG VALUE (actual metered weight in batch, xxx.xxx)

9 (R) hop2_displayed_actual_weight,D1096,LONG VALUE (actual metered weight in batch, xxx.xxx)

10 (R) hop3_displayed_actual_weight,D1098,LONG VALUE (actual metered weight in batch, xxx.xxx)

11 (R) hop4_displayed_actual_weight,D1100,LONG VALUE (actual metered weight in batch, xxx.xxx)

12 (R) hop5_displayed_actual_weight,D1102,LONG VALUE (actual metered weight in batch, xxx.xxx)

13 (R) hop6_displayed_actual_weight,D1104,LONG VALUE (actual metered weight in batch, xxx.xxx)

882.00207.00 Chapter 7: Appendix 98 of 102

Alarm Number Explanation:

The alarms are given in individual bits and are reflected in the alarm number. The alarm number is only
used to drive a pop-up message and will probably not be very useful to you. If you decide to use the
alarm number instead of reading the individual alarm bits then the related values are shown below:

D1876 Value Alarm Description

0= NO ALARM

1= HOPPER 1 Out of Material 1

2= HOPPER 2 Out of Material 2

3= HOPPER 3 Out of Material 3

4= HOPPER 4 Out of Material 4

5= HOPPER 5 Out of Material 5

6= HOPPER 6 Out of Material 6

7= POWER INTERRUPTION while metering a Batch

8= PLC BATTER LOW Check PLC and Configure the Blender

9= MAX HOPPER WEIGHT EXCEEDED. CHECK BATCH SIZE

10= CALIBRATION ERROR. Clean out weigh hopper and check calibration

12= HOPPER 1 Low Level

13= HOPPER 2 Low Level

14= HOPPER 3 Low Level

15= HOPPER 4 Low Level

16= HOPPER 5 Low Level

17= HOPPER 6 Low Level

FIXED DECIMAL EXPLANATION

All weight values and recipe values use fixed decimal. This must be taken into consideration when
writing or reading values. If you see “xxx.xxx” above this means the data is in fixed decimal and must
be scaled when reading or writing. A decimal is shown next to each item to represent the format.

WRITING RECIPE EXPLANATION

To write a recipe you must first write to the “temp recipe” value locations above. After this is complete
you should read the “accept recipe enabled” and the “recipe error” values. If you have a recipe error
then you should display the appropriate text. If the “accept recipe enabled” is high then show a button
that will then write to “accept recipe” bit. This will load in the recipe. You do not need to check the
sum of the recipe that they’ve entered. The blender will do that for you.

882.00207.00 Chapter 7: Appendix 99 of 102