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Mitsubishi Electronics 882.00207.00 manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    Gravimetric Slide Gate Batch Blender Mitsubishi Controller Part Number: 882.00207.0 0 Bulletin Number: BF1-615 Effective: 02/01/06 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We ar[...]

  • Page 2

    Please note that our address and phone i nformation has changed. Please reference this page for updated contact information. These manuals are obsolet e and are provided only for their technical inf ormation, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, main tenanc e and repair of [...]

  • Page 3

    882.00207.00 ii Shipping Info Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contrac[...]

  • Page 4

    882.00207.00 iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping departme nt. Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be giv[...]

  • Page 5

    882.00207.00 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ..................................................................... 7 1[...]

  • Page 6

    882.00207.00 v 3-3 Electrical Connections ............................................................................................... 34 3-4 Pneumatic Connections ............................................................................................ 34 3-5 Initial Set-up ....................................................................[...]

  • Page 7

    882.00207.00 vi Customer Responsibilities ................................................................................... 71 7-2 Technical Specifications ............................................................................................ 72 Equipment Specifications .......................................................................[...]

  • Page 8

    882.00207.00 Chapter 1: Safety 7 of 102 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 a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main tenance. N[...]

  • Page 9

    882.00207.00 Chapter 1: Safety 8 of 102 Figure 1: Safety Tags and Warning Labels Tag Description Tag Description Pinch Point Slide Gate Read Operation & Installation Manual Shear Point Rotating Mixer Earth Ground High Voltage Inside Enclosure PE Protected Earth Ground Shear Hazard Rotating Auger Lifting Point[...]

  • Page 10

    882.00207.00 Chapter 1: Safety 9 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 a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regul[...]

  • Page 11

    882.00207.00 Chapter 1: Safety 10 of 102 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with its operati[...]

  • Page 12

    882.00207.00 Chapter 1: Safety 11 of 102 Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report any potentially dangerous s ituation to your supervisor or app ropriate person. REMEMBER: • NEVER place your hands or any part of your body in any dangerous location. • NEVER operate, service, or [...]

  • Page 13

    882.00207.00 Chapter 1: Safety 12 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 equipm[...]

  • Page 14

    882.00207.00 Chapter 2: Functional Description 13 of 102 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for slide gate blenders of various blending rates and specifica tions. See below for a list of available models. • 150 lbs/hr Slide Gate Batch Blen[...]

  • Page 15

    882.00207.00 Chapter 2: Functional Description 14 of 102 Figure 2: Equipment Specifications 150 500 900 2500 4000 6000 150 (68) 500 (227) 900 (4 10) 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[...]

  • Page 16

    882.00207.00 Chapter 2: Functional Description 15 of 102 2-3 Typical Featur es and Components Mechanical Features • Exclusive diamond design slide gate meteri ng 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 pou[...]

  • Page 17

    882.00207.00 Chapter 2: Functional Description 16 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[...]

  • Page 18

    882.00207.00 Chapter 2: Functional Description 17 of 102 Slide Gates Air operated slide gates are provided to meter the majority of pellet ingredients on Slide Gate blenders. A stroke limiter (included) can be installed on the metering gates to lim it their travel. This device decreases the stroke of the gate and reduces the metering orifice of the[...]

  • Page 19

    882.00207.00 Chapter 2: Functional Description 18 of 102 Figure 6: Typical Slide Gate Assembly Each of the diamond gate air cylinders is actuate d by a solenoid valve, which is controlled by the blender controller. When the solenoid valve is energized, it opens the metering valve cylinder. Whe n the solenoid valve is de-energized, it closes the met[...]

  • Page 20

    882.00207.00 Chapter 2: Functional Description 19 of 102 Figure 7: Typical Weigh Hopper Assembly The weigh hopper dump door holds the material until it is dumped into the m ixing section. The cylinder is actuated by a solenoid in the va lve stack on the side of the blender. In looking at the pneumatic circuit, you can see that the air regulator con[...]

  • Page 21

    882.00207.00 Chapter 2: Functional Description 20 of 102 Mix Chamber All of the batch blenders are equipped with an integr al mix chamber. The mix cham ber 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-direc tional mixing action an[...]

  • Page 22

    882.00207.00 Chapter 2: Functional Description 21 of 102 Figure 9: Typical Mitsubishi Controller Touch Screen Display Figure 10: Controller Pushbuttons & Touchscreen Tags Button Function (Power On) Turns power on to the blender controller. (Found on the back of the controller). (Power Off) Turns power off to the blender controller. (Found on th[...]

  • Page 23

    882.00207.00 Chapter 2: Functional Description 22 of 102 Figure 11: Typical Operator Screens[...]

  • Page 24

    882.00207.00 Chapter 2: Functional Description 23 of 102 Figure 12: Typical Setup Screens[...]

  • Page 25

    882.00207.00 Chapter 2: Functional Description 24 of 102[...]

  • Page 26

    882.00207.00 Chapter 2: Functional Description 25 of 102 2-4 Optional Components The following is a list of options that yo ur blender may have been equipped with. Pneumatic Slide Gate below Mixer The Slide Gate/Auger blending system can be equipped with an optional pneumatic slide gate below the mixing chamber. The gate is used in applica tions wh[...]

  • Page 27

    882.00207.00 Chapter 2: Functional Description 26 of 102 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 Additi[...]

  • Page 28

    882.00207.00 Chapter 2: Functional Description 27 of 102 2-5 Safety Features This section includes information on important safety devices and procedures relating to the Gravimetric Batch Blender. This manual is not in tended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this se[...]

  • Page 29

    882.00207.00 Chapter 2: Functional Description 28 of 102 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 tu rning while the auger unit is being serviced or cleaned[...]

  • Page 30

    882.00207.00 Chapter 2: Functional Description 29 of 102 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[...]

  • Page 31

    882.00207.00 Chapter 3: Installation 30 of 102 Chapter 3: Inst allation 3-1 Uncrating the Equipment Slide Gate/Auger Blenders are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a crate. 1. Remove crate from around blender. 2. Secure strap of proper lifting capacity to both lifting lugs. (See Figure 20 below). Caution! Us[...]

  • Page 32

    882.00207.00 Chapter 3: Installation 31 of 102 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 suppl y hoppers. 6. Align the weigh hopper on the load cell brackets. Carefully adjust the load cell brackets to ensure that the weigh hopp[...]

  • Page 33

    882.00207.00 Chapter 3: Installation 32 of 102 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 f asten horizontal or angled braces to the blender if more stability is needed. Take care to insure proper orientation with adequate access to operat[...]

  • Page 34

    882.00207.00 Chapter 3: Installation 33 of 102 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 ade quate clearance for all blender operations and maintenance. The operator and maintenance personne l m ust have acce[...]

  • Page 35

    882.00207.00 Chapter 3: Installation 34 of 102 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 curre nt requirements vary with the blender’s size and throughput rating. For exact current requirem ents, check the blender serial [...]

  • Page 36

    882.00207.00 Chapter 3: Installation 35 of 102 The manufacturer provides all pneumatic lines on th e blender piped to a single ¼” NPT standard pipe thread fitting. The Slide Gate/Auger blending s ystem 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 cyli[...]

  • Page 37

    882.00207.00 Chapter 3: Installation 36 of 102 Figure 25: Weigh Hopper Final Connections 1. Connect the blender to the appropriate power source. 2. Connect the compressed air pi ping, ensuring that a 5-m icron air filter is installed, along with the proper water trap, and lubrication unit, if require d. Verify that 60 psi (4.14 bar) of clean, dry c[...]

  • Page 38

    882.00207.00 Chapter 3: Installation 37 of 102 This screen displays the software version of both the PLC and the Panel View. The Controller will stay on this screen for about 10 seconds or you can touch the pictur e of the blender to quickly skip to the Recipe Screen (Next Screen in sequence). The software versions are also available on the Panel V[...]

  • Page 39

    882.00207.00 Chapter 3: Installation 38 of 102 Blender Controller Menu Structure “Recipe Book” Page ¾ Sav e the running recipe to the book ¾ Delet e a stored re cipe ¾ Load a stored r ecipe ¾ Erase all stored recipes ¾ Modify the product ID for a stored re cipe ¾ Return to the “ Recipe” page “Clean Out” Page ¾ Empty the blende r [...]

  • Page 40

    882.00207.00 Chapter 3: Installation 39 of 102 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. T hey [...]

  • Page 41

    882.00207.00 Chapter 3: Installation 40 of 102 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 rem ove the weight hopper and press OK. 5. After touching OK, the controller will display “PLEASE WAIT...?[...]

  • Page 42

    882.00207.00 Chapter 3: Installation 41 of 102 5. Add the calibration weight to each load ce ll 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 calibratio[...]

  • Page 43

    882.00207.00 Chapter 3: Installation 42 of 102 4. The current settings for the hopper that you ha ve chos en 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 set[...]

  • Page 44

    882.00207.00 Chapter 3: Installation 43 of 102 Additional Setup Parameters The settings listed below are set at the fact ory 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. 2. Touch the “Mixer and Dump Setup” key to en ter the amount of[...]

  • Page 45

    882.00207.00 Chapter 3: Installation 44 of 102 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, de pending on whether the blender is currently runnin g or is stopped. Simply touch the button t o either start or stop the blender. I[...]

  • Page 46

    882.00207.00 Chapter 4: Operation 45 of 102 Chapter 4: Operation 4-1 Start-up General Operation The general operation of the Slide Gate/Auger ble nding 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 inform ation.[...]

  • Page 47

    882.00207.00 Chapter 4: Operation 46 of 102 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 s hown 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 accep[...]

  • Page 48

    882.00207.00 Chapter 4: Operation 47 of 102 Figure 33: Typical Recipe Entry Operator Screen A typical menu is shown in the figure above. This di splay, which is defaulted to when the controller is turned on, provides the operator with the following inform ation and options: • The ability to change Recipe Values • Accept a newly entered Recipe ?[...]

  • Page 49

    882.00207.00 Chapter 4: Operation 48 of 102 specified amount. The ingredient weights (Unit Va lues) are in pounds, unless the metric display is selected. Pressing the “NEXT” key when in the default reci pe 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 critic[...]

  • Page 50

    882.00207.00 Chapter 4: Operation 49 of 102 to have values entered (Percentage or Parts r ecipe 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 • [...]

  • Page 51

    882.00207.00 Chapter 4: Operation 50 of 102 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 availab[...]

  • Page 52

    882.00207.00 Chapter 4: Operation 51 of 102 “Percentage” Mode (Most common in Extrusion and Blow Molding) Extrusion processing often requires recipes in per centage 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 1[...]

  • Page 53

    882.00207.00 Chapter 4: Operation 52 of 102 Because the blending systems must handle a wide va riety 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 [...]

  • Page 54

    882.00207.00 Chapter 4: Operation 53 of 102 To enable this feature , simply enter a desired shutdown we ight value (from 1 to 999999999) into the Inventory Shutdown display line of the Recipe Form at screen, under the Setup menu. This feature can be configured while the blender is making a batch. If the Inventor y Shutdown is changed, then you will[...]

  • Page 55

    882.00207.00 Chapter 4: Operation 54 of 102 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 m ixing needed for the materials being blended. It is recommended that the mix time be held to the minimum, as segregation can occur from over- mixing if the material bulk density an[...]

  • Page 56

    882.00207.00 Chapter 4: Operation 55 of 102 Weigh Hopper Dump Cycle The dump cycle allows the weigh hopper dump valve to c ycle or open and close a number of times prior to commencing with the next batch cycle. The s etting allows from 1 to 9 dump cycles between batches (open and closed cycles). The normal and default factory setting is 1, m eaning[...]

  • Page 57

    882.00207.00 Chapter 4: Operation 56 of 102 Max Hopper Weight Exceeded, Check Batch Size This alarm indicates that the weight in the weigh hopper has exceeded the ma ximum allowed weight. This alarm can happen if the operator changes ma terial density and does not perform a feeder calibration, but will usually be automatically fixed afte r the firs[...]

  • Page 58

    882.00207.00 Chapter 4: Operation 57 of 102 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 Batter y Low” Alarm Scree n Blender Powered On/Off These are only logged in the Alarm Log and does not cause a pop-up m essage or audible al[...]

  • Page 59

    882.00207.00 Chapter 4: Operation 58 of 102 Feeder Clean Out Any feeder in the Slide Gate/Auger blending system can be emptied and re filled with a different material. To do a feeder clean out, the operator h as to press the “Clean Out” icon key from the recipe screen (the first screen that appears when powered up). This screen will allow you t[...]

  • Page 60

    882.00207.00 Chapter 4: Operation 59 of 102 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 st art 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 t[...]

  • Page 61

    882.00207.00 Chapter 4: Operation 60 of 102 Figure 42: Typical Recipe Book Operator Screen Save Running Recipe to the Book The save current recipe to book function allows th e 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 pr om pted for a reference r[...]

  • Page 62

    882.00207.00 Chapter 4: Operation 61 of 102 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 f or that recipe should be currently displayed on the screen. The controlle r will only prompt the oper[...]

  • Page 63

    882.00207.00 Chapter 4: Operation 62 of 102 7. Using a vacuum cleaner or air hose, clean out all t he hoppers that have been emptied. Always start at the uppermost part of the bl ender and work downward to prevent dust and pellets from falling into an already cleaned area. WARNING! The auger metering assemblies on Aug er blenders can be removed aft[...]

  • Page 64

    882.00207.00 Chapter 5: Maintenance 63 of 102 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of the blender is very simp le and very little maintenance is required. The only moving parts are the metering gates, wei gh hopper dump valve, and m ixer agitator. The checklist below contains a list of items which s hou[...]

  • Page 65

    882.00207.00 Chapter 5: Maintenance 64 of 102 5-2 Preventative Maintenance Our blenders need periodic maintenance to prov ide 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 lub[...]

  • Page 66

    882.00207.00 Chapter 5: Maintenance 65 of 102 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 we igh hopper load cells. This, of course, does not include the operator touchscreen input. The mix hopper high level [...]

  • Page 67

    882.00207.00 Chapter 6: Troubleshooting 66 of 102 Chapter 6: T roubleshooting 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 norma l troubleshootin g must be accomplished with the power off, line fuses removed, and with the machine tagged as [...]

  • Page 68

    882.00207.00 Chapter 6: Troubleshooting 67 of 102 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 rem ain constant with all the m otors starting and stopping. Insure that the blender is on a “clean” circuit that doe[...]

  • Page 69

    882.00207.00 Chapter 6: Troubleshooting 68 of 102 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 batch size. If this is correct, then you are probably not accounting for material scrap or other items in your process. Recorded Inventory [...]

  • Page 70

    882.00207.00 Chapter 6: Troubleshooting 69 of 102 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 [...]

  • Page 71

    882.00207.00 Chapter 6: Troubleshooting 70 of 102 Problem Corrective action I can’t calibrate the Scale without an error message. This is caused by the difference in bits not being large enough. Using the Direct Scale Readout, ex amine current loadcell bits with and without the calibration weight. If the bits do not change significantly, then che[...]

  • Page 72

    882.00207.00 Chapter 7: Appendix 71 of 102 Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product incl udes a standard ONE YEAR PARTS WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free fro m defects in workmanship and material when used under recommended condit[...]

  • Page 73

    882.00207.00 Chapter 7: Appendix 72 of 102 7-2 Technical Specifications Equipment Specifications Figure 46: Equipment Specifications 150 500 900 2500 4000 6000 150 (68) 500 (227) 900 (4 10) 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)[...]

  • Page 74

    882.00207.00 Chapter 7: Appendix 73 of 102 Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equi pment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity 4. Altitude: Se[...]

  • Page 75

    882.00207.00 Chapter 7: Appendix 74 of 102 7-3 Drawings and Diagrams Final Assembly Figure 47: Typical Final Assembly Parts List # Description 150 900 2500 4000 6000 1 Mixer Assembly A0771677 A0771682 A0771683 A0771663 A0771691 A0771692 3-Component Hopper Assembly N/A A0771687 A0771664 A0771700 2-Component Hopper Assembly N/A A0771686 A0771665 A077[...]

  • Page 76

    882.00207.00 Chapter 7: Appendix 75 of 102 Mixer Sub-Assembly[...]

  • Page 77

    882.00207.00 Chapter 7: Appendix 76 of 102 Figure 48: Typical Mixer Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 FRAME 872.00093.00 872.00094.00 A0770301 872.00224.00 2 FRAME EXTENSION (NOT SHOWN) N/A 872.00225.00 3 TOP PLATE 872.00095.00 872.00096.00 A0770300 872.00226.00 4 MOUNTING BRACKET – MIXER MOTOR 872.00097.00 872.00098.00 A[...]

  • Page 78

    882.00207.00 Chapter 7: Appendix 77 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 3 LEXAN DOOR A0770286 4 DOOR LATCH A0770076 5 3.5” SIGHT GLASS A0569154 N/A 6 4.5” SIGHT G[...]

  • Page 79

    882.00207.00 Chapter 7: Appendix 78 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 1 THROAT 07822-1 2 CLAMP A0548808 3 FEEDER TUBE # 872.00426.00 # 4 DRAIN HOUSING 08806A-HYD 5 DRAIN SLIDE GATE 08806B 6 MOTOR MOUNT BRACKET 08451 7 SEAL ?[...]

  • Page 80

    882.00207.00 Chapter 7: Appendix 79 of 102 Hopper Additive Feeder Sub-Assembly (Optional) Figure 51: Typical Additive Feeder Hopper Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 THROAT A0541201 2 MOTOR MOUNT BRACKET A0541229 3 MOTOR – AUGER 51450G 4 THROAT ADAPTER – 2” RISER 872.00537.00 N/A HOPPER 1.0 CU.FT. A0541207 N/A 5 HOPPE[...]

  • Page 81

    882.00207.00 Chapter 7: Appendix 80 of 102 Weigh Hopper Sub-Assembly Figure 52: Typical Weigh Hopper Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 WEIGH HOPPER 872.00103.00 872. 00104.00 A0770312 872.00229.00 872.00230.00 2 AIR CYLINDER 245.00003.00 A0770248 3 CLEVIS – AIR CYLINDER 35460 35449 4 FITTING – AIR TUBING 35086K 35085K 5[...]

  • Page 82

    882.00207.00 Chapter 7: Appendix 81 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 872.00235.00 GATE – DIAMO[...]

  • Page 83

    882.00207.00 Chapter 7: Appendix 82 of 102 Knife Gate Sub-Assembly HD (Optional) Figure 54: Typical Knife Gate (bel ow mixer) Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 BASE FRAME 07990 2 MOLDED THROAT 53413 3 SPACER PLATE 08286 4 FLANGE ADAPTER 08292 5 KNIFE BLADE 10644 6 MOUNTING BRACKET – AIR CYLINDER 33088 7 AIR CYLINDER 33091[...]

  • Page 84

    882.00207.00 Chapter 7: Appendix 83 of 102 Knife Gate Sub-Assembly RD (Optional) Figure 55: Typical Knife Gate (floor stand) Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 HOUSING FRAME 872.00297.00 2 GUARD SAFETY COVER 872.00236.00 3 ROD GUIDE 832.00049.00 4 GATE – SLIDE BLADE 872.00236.00 5 AIR CYLINDER 245.00016.00 6 CLEVIS – AIR[...]

  • Page 85

    882.00207.00 Chapter 7: Appendix 84 of 102 Control Panel Layout Figure 56: Typical Mitsubishi Controller Main Parts List # Description 150 500 900 2500 4000 6000 1 Mitsubishi PLC FX2N-32MR A0569702 2 Mitsubishi PLC EEPROM A0569703 3 24 vdc Power Supply A0563932 4 Calex Module – Load Cell Amplifier 724.00117.00 5 Alarm Light Yellow Strobe 24 vdc A[...]

  • Page 86

    882.00207.00 Chapter 7: Appendix 85 of 102 7-4 Spare Parts Kits Figure 58: Blender Spare Parts Listing M odel 150 500 900 2500 4000 6000 KIT "A" (Consu mables) A 0574120 A 0574134 A 0574137 A 0574125 A0574140 A 0574143 Load Cell Assem bl y (wi thout pl ug) # 724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00 Mixer High Level[...]

  • Page 87

    882.00207.00 Chapter 7: Appendix 86 of 102 7-5 Addendum (Service Supervisor Information) This section of the manual should not b e 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 inexp erienced plant [...]

  • Page 88

    882.00207.00 Chapter 7: Appendix 87 of 102 Typical Engineering Only Setup Screen 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 [...]

  • Page 89

    882.00207.00 Chapter 7: Appendix 88 of 102 Typical Advanced Weight Options Screen Feed Algorithm Options Screen This screen allows the user to configure how th e 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 Wei[...]

  • Page 90

    882.00207.00 Chapter 7: Appendix 89 of 102 Mechanical Options Screen This screen allows the user to change the number of hoppers, the pr edeterm ined 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[...]

  • Page 91

    882.00207.00 Chapter 7: Appendix 90 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 Targ et vs. Actual data can be configured for either regardless of the blender’s units. Typical Units Screen Network Setup This scre[...]

  • Page 92

    882.00207.00 Chapter 7: Appendix 91 of 102 Alarm Setup This screen allows the user to configure the feeder type for each feeder; configure whether a f eeder 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 bl ender will continue to meter th[...]

  • Page 93

    882.00207.00 Chapter 7: Appendix 92 of 102 Factory Default Setup Parameters Model Number 150 500 900 2500 4000 6000 Recipe Entry Mode PERCE NTAGE Metering Order Batch Siz e (lbs ) 2.0 4.0 8.0 25.0 35.0 45.0 Inventory Shutdown Batch Ready Mode A utoStart Mode Weighi ng m ode Blender Number A uto Print Inventor y A uto Clear Inventor y A uto Print/Cl[...]

  • Page 94

    882.00207.00 Chapter 7: Appendix 93 of 102 Model Number 150 500 900 2500 4000 6000 Hop1 Initial % of Target 100 Hop2 Initial % of Target 99 Hop3 Initial % of Target 100 Hop4 Initial % of Target 99 Hop5 Initial % of Target 99 Hop6 Initial % of Target 99 Hop7 Initial % of Target 99 Hop8 Initial % of Target 99 Hop1 Allowed Underfeed (lbs) 0.001 Hop2 A[...]

  • Page 95

    882.00207.00 Chapter 7: Appendix 94 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[...]

  • Page 96

    882.00207.00 Chapter 7: Appendix 95 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) emp[...]

  • Page 97

    882.00207.00 Chapter 7: Appendix 96 of 102 INVENTORY INF O 1 (RW) clear_inventory,M503 (toggle this to clear all inve ntor y, you must also reset this bit after completion) 2 (RW) batch_counter,D1336,LONG VA LUE (number of batches made) 3 (R) hop1_inventory,D12 74,LONG VALUE (this is the whole portion of the inventory) 4 (R) hop2_inventory,D12 76,L[...]

  • Page 98

    882.00207.00 Chapter 7: Appendix 97 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 VAL UE (xxx.xx, write your new recipe her[...]

  • Page 99

    882.00207.00 Chapter 7: Appendix 98 of 102 RECIPE BOOK MANIPULATION 1 (RW) recipe_book_number, D2088, S HORT VALU E (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 g[...]

  • Page 100

    882.00207.00 Chapter 7: Appendix 99 of 102 Alarm Number Explanation: The alarms are given in individual bits and are reflect ed 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 alar m bits then the related[...]

  • Page 101

    882.00207.00 Chapter 7: Appendix 100 of 102 RECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH The targets that are read are in lb s or kgs. When a batch is complete and dumped the blender will toggle high the “print data now” bit. At this time you should then read the “actual displayed weights” values and record them into a log or chart. If [...]

  • Page 102

    882.00207.00 Chapter 7: Appendix 101 of 102 7-7 Technical Assistance Parts Department Call Spare Parts Express toll-free 8am-5pm CST (800) 423-3183. OEM quality replacement and spare parts ensure operation at design specifications. Please have the model and serial nu mber of your equipment when you call. Consult the Customer Parts List included in [...]

  • Page 103

    882.00207.00 Chapter 7: Appendix 102 of 102[...]