Mitsubishi Electronics 882.00273.00 manual

Gravimetric Slide Gate Batch Blender Mitsubishi Controller Part Number: 882.00273.0 0 Bulletin Number: BF1-615.3 Effective: 11/07/07 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We [...]

BF1-615.3 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 m ounting screws, etc. In the Event of Shipping Damage According to the contract [...]

BF1-615.3 iii Credit Returns Prior to the return of any material, authorization m ust be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL r[...]

BF1-615.3 iv Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ..................................................................... 7 1-2 [...]

BF1-615.3 v 3-5 Initial Set-up .............................................................................................................. 35 Mechanical Set-up ............................................................................................... 35 Stroke Limiters for Metering Gates .....................................................[...]

Hopper Additive Feeder Sub-Assembly (Optional).............................................. 79 Weigh Hopper Sub-assembly .............................................................................. 80 Slide Gate Sub-assembly .................................................................................... 81 Knife Gate Sub-assembly HD (Option[...]

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. No other maintenance should be undertaken[...]

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 BF1-615.3 Chapter 1: 0BSafety 8 of 101[...]

1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd 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 injur[...]

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 operation as described in this manual. Proper op[...]

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 adjust the blender without appropriate tr[...]

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 m achine, and disconnect and l[...]

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 Blender with Mitsubishi Controls • 500 lbs/hr Slide Gate Ba[...]

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 (3.6) 25 (11.3) 35 (15. 8) 45 (2 0.4 ) 1 @ 5 kg 2 @ 3 [...]

2-3 Typical Features 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#) • Removable Stainless steel weigh hopper and mixing compo[...]

• 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[...]

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” diam eter 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 c[...]

Figure 6: Typical Slide Gate Assembly Each of the diamond gate air cylinders is act uated by a solenoid val ve, which are controlled by the blender controller. When the solenoid valve is energized, it opens the me tering valve cylinder. When the solenoid valve is de-energized, it closes the metering valve cylinder. If the power is interrupted to th[...]

Figure 7: Typical Weigh Hopper Assembly The weigh hopper dump door holds the material until it is dum ped 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 h[...]

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-d irectional mixing action and can be easily taken apart for cleaning. This design is [...]

Figure 9: Typical Mitsubishi Controller Touch Screen Display Note: The touch-screen panel display on your unit may be slightly different than shown. Figure 10: Controller Pushbuttons & Touchscreen Tags Button Function (Power On) Turns power on to the blender controller. (Found on the back of the controller.) (Power Off) Turns power off to the b[...]

Figure 11: Typical Operator Screens BF1-615.3 Chapter 2: 1BFunctional Description 22 of 101[...]

Figure 12: Typical Setup Screens BF1-615.3 Chapter 2: 1BFunctional Description 23 of 101[...]

BF1-615.3 Chapter 2: 1BFunctional Description 24 of 101[...]

2-4 Optional Components The following is a list of options, which y our 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 applications when the blender is m ounted above a large hopper, or for [...]

Regrind Auger Metering (R.A.M.) Hopper Used for feeding difficult regrind materials . Figure 15: Typical R.A.M. Hopper Blender Configuration Additive Feeder Hopper Used for feeding pelletized additive, typically used on blenders with more than six components. Figure 16: Typical Additive Feeder Configuration Take-off Compartments Allows material to [...]

2-5 Safety Features This section includes information on safety devices and procedures that are inherent to the Gravimetric Batch Blender. This manual is not in tended 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 ord[...]

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 av ailable at most electrical supply stores. Figure 17: Electrical Disconnect Plug Twist Cap Plug Connected to Each Feeder Auger Motor The cap plug must be turned counter-clockwise to loosen and the female end of the[...]

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. compres[...]

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

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 br ackets. Carefully adjust the load cell brackets to ensure that the weigh hopper is centered on the brackets without rocking[...]

Using proper lifting equipment, lift the blender, us ing the lifting lugs attached to the top plate of the blender. These lifting lugs can also be u sed 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. Take care to insure proper orientation with ad[...]

If possible, use rigid tubing. Some flex hose will tend to sag and generate static that could cause de-mixing between the blender and the extruder. 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 clearanc[...]

3-3 Electrical Connections The standard Slide Gate/Auger blending syst em is designed to oper ate on 120/1/60 suppl y voltage (220/1/50 CE models are also availa ble). The current requi rements 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 [...]

The manufacturer provides all pneumatic lines on the blender piped to a single ¼” NPT standard pipe thread fitting. The Slide Gate/A uger blending system requires approxim ately 1 cfm (1.7 m³/hr) @ 60 psi (4.14 bar) maximu m air pressure for proper operation. The working pressure of the blender cylinders is not to exceed 60 psi (4.14 bar). This[...]

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. Figure 25: Weigh Hopper Note: THE WEIGH HOPPER ASSEMBL Y MUST HANG FREELY AND BE FREE FROM FRICTION, WI TH NO MECHANI CAL OBSTRUCTIONS OTHER THAN T HE L OA[...]

This screen displays the software version of bo th the PLC and the PanelView. The Controller will stay on this screen for about 10 seconds or you can touch the picture of the blender to quickly skip to the Recipe Scr een (Next Screen in sequence). The software versions are also available on the Panel View Configuration Screen. Figure 27: Display Ma[...]

Blender Controller Menu Structure 101 “Recipe Book” Page ¾ Sav e the running recipe to the book ¾ Delete 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 “ R eci pe” page “Clean Out” Page ¾ Empty the blende r hopper( s) ¾ Manually Operate the mixer, [...]

Blender Calibration The load cells on the Auger blender are FACTORY CALIBRATED. Since the load cells can be subject to shock loading during shippi ng, moving, e tc., 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 a dded t[...]

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 t o 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[...]

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 st ep 5. This is the measured weight. If the measured weight is within a 0.003 pounds of the weight stam ped on the calibration weight, then you are within spec. If not, fo[...]

3. Select a feeder (1-6) by to uching the “Select Feeder” box. 4. The current settings for the hopper that you have chos en will now be shown on the screen. 5. Make the necessary adjustments to the “St op/Continue if “Out of Material,” Alarm/No Alarm on “Out of Material,” and Out of Material Alarm Silence Delay (0- 60 seconds) setting[...]

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 Manuf acturer’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 [...]

3-6 Initial Startup The operator can startup the blender by selecting the button that says, “Push to St art 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 t[...]

Chapter 4: Operation 4-1 Start-up General Operation The general operation of the Slide Gate/Auge r 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 th is manual for further information. Once the Slide Gate/Auger blending system i[...]

Note: The blender monitors the operator’s en tries and de termin es if the recipe is valid before accepting the new recipe. If there is an error (such as the recipe does not add up to 100% and the blender is in Percentage Mode.) then a message is shown on the Recipe screen to alert the opera tor of the problem. The “Accept New Recipe” button [...]

Operator Displays The Slide Gate/Auger blending system utilizes a standardized menu format. Each screen was designed to be user-friendly and provide th e operator with the necessary information to run the blender. Figure 33: Typical Recipe Entry Operator Screen A typical menu is shown in the figure above. This display, which is defaulted to when th[...]

While the blending system is in operation, there are a couple of dis plays 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 ble nder is in run mode is the Recipe Screen. The Recipe Screen indicates by feeder number, the am ount of material meter[...]

Upon Start Up, the blender controller w ill 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, Pe rcentag[...]

“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 com ponents) . 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 opera[...]

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% [...]

“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 100%. If the y don’t, an e rror message app[...]

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 to 99.9.[...]

To enable this feature , simply enter a desired shutdown weight value (from 1 to 999999999) into the Inventory Shutdown displa y line of the Recipe Format screen, under the Setup m enu. This feature can be configured while the bl ender is making a batch. If the Inventor y Shutdown is changed, then you will need to touch “Accept New Recipe” on t[...]

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. 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 mi xing n eeded for the materials being blended. It is[...]

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 ba tch 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 t[...]

Max Hopper Weight Exceeded, check batch size: This alarm indicates that the weight in the weigh hopper has exceeded the maximum allo wed 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 cont[...]

PLC Battery Low: PLC battery is low and may cause the blender to lose both the program and the blender configuration. Notify Maintenance immediately. Figure 45: Typical “PLC Battery Low” Alarm Screen PLC BATTERY LOW Blender Powered On/Off: These are on ly logged in the Alarm Log and does not cause a pop-up message or audible alarm . Each time t[...]

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 on power up). This screen will allow you to Open or Close the Feeder, Weigh Hopper, Mixer Kn[...]

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 dum p cycle. 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 mi xer will start before the weigh hopper dum [...]

Figure 48: Typical Recipe Book Operator Screen Erase One Stored Recipe Select a Store d Recipe Stored Recipe Details Erase Entire Book Load Stored Recipe Go to Recipe Page 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.[...]

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. 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 o ne recip[...]

8. If any other ingredients need to be changed for the next recipe, simpl y 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[...]

Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of the blender is very si mple and very little maintenance is required. The only moving parts are the metering gates, weigh hopper d ump valve, and mixer agitator. The checklist below contains a list of items wh ich should be inspected and/or replaced to keep your bl[...]

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[...]

Input Signals to Programmable Controller The Slide Gate/Auger blending system has tw o main input signals that it uses from the blending process: the mix hopper high le vel signa l 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 pr oximity level se[...]

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 normal trouble-shooting m ust be accomplished with the power off, line fuses rem oved, and with the machine tagged as out of service. The use of good quality test equi[...]

Problem Corre ctive 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 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 [...]

Problem Corre ctive 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 Totals don’t match what I’ve actually used So[...]

Problem Corre ctive 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 t[...]

Problem Corre ctive 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 check for pe llets jamming the loadcells and check t[...]

Chapter 7: Appendix 7-1 Technical Specifications Equipment Specifications Figure 52: 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 )[...]

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: Sea level 5. Environment: Clean, dust-free an[...]

7-2 Drawings and Diagrams Final Assembly Figure 53: 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 A0771699 Removable Hopper Small CTB01648 N/A 2 [...]

Mixer Sub-Assembly BF1-615.3 Chapter 7: 6BAppendix 75 of 101[...]

Figure 54: 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 A0770316 5 MIX CHAMBER BACK PLATE 872. 00099[...]

Hopper Sub-assembly Figure 55: 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 GLASS N/A A0770323 (OPTIONAL) 2” DRAIN W/ [...]

Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional) Figure 56: 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 – AUGER - TEFLON 55372 8 MOTOR - AUGER 720[...]

Hopper Additive Feeder Sub-Assembly (Optional) Figure 57: 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 HOPPER 2.0 CU.FT. N/A A0541208 6 SIGHTGLASS – [...]

Weigh Hopper Sub-assembly Figure 58: 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 AIR TUBING (NOT SHOWN) 35300K BF1-615.3 Ch[...]

Slide Gate Sub-assembly Figure 59: 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 – DIAMOND (#1-4) A0770309 A0770305 872.00237.00 GA[...]

Knife Gate Sub-assembly HD (Optional) Figure 60: 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 8 - - 9 MOUNTING NUT – AIR CYLINDER A055[...]

Knife Gate Sub-assembly RD (Optional) Figure 61: Typical Knife Gate (floor stand) Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 HOUSING FRA ME 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 CYLINDER A0770296 7 NUT – LOCKING A0533[...]

Control Panel Layout Figure 62: 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 A0565889 6 Alarm Horn 95db 24vdc A0542574 Gl[...]

7-3 Spare Parts Kits Figure 64: Blender Spare Parts Listing M ode l 150 500 900 2500 4000 6000 KIT "A " (Consumable s) A 0574120 A 0574134 A 0574137 A 0574125 A0574140 A 0574143 Load Cell Assem bly (wit hout pl ug) # 724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00 Mixer High Level Sensor # (5 ) F u s e s , 1 .5 A m p (5 )[...]

7-4 Addendum (Service Supervisor Information) Note: This section of the manual should not be used by untrained personnel – blender controller and/or program can be compromised! Note: Hidden, programmable features and hidden menu pages should not be made available to floor operators. These pages include the Service Supervisor Information addendum [...]

Figure 66: Typical Engineering Only Setup Screen Go back to Setup Directory 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 au[...]

This setting should not be m odified exce pt by the developer except under unusual circumstances. Figure 68: Typical Advanced Weight Options Screen 101 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 [...]

Mechanical Options Screen This screen allows the user to change the number of hoppers, the predeterm ined gate cycle time, and the mixer bump time for detecting hi gh 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 s[...]

Customer Setup Menu Units This screen allows the user to change the ble nder’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. Figure 73: Typical Units Screen Network Setup This screen allows the blender to be confi[...]

Alarm Setup This screen allows the user to configure the f eeder 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 Re try” then the blender will continue to m eter the rest of the batch even if this hopper ru[...]

Factory Default Setup Parameters Model Number 150 500 900 25 00 4000 6000 Recipe Entry Mode PERCENT AGE 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 Weighing mode Blender Number A uto Print Inventor y A uto Clear Inventor y A uto Print/Clear Interva l Start Hour Hop1 wt/ sec (lb s [...]

Model N umber 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 All owed Underfeed (lbs) 0.001 Hop2 All owed Underfeed (lbs) 0.001 Hop3 All ow[...]

7-5 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 Et hernet speed is 10 Mbits/s econd. 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 afterwa[...]

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_cl[...]

INVENTORY INF O 1 (RW) clear_inventory,M503 (toggle this to clear a ll inventory, 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,LONG VALUE (this is the whole portion of the [...]

RECIPE INFO (THIS IS WHERE YOU RIGHT THE NEW RECIP E TO) 1 (RW) temp_recipe_entry_mode,D1706, SHORT VA LUE (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 here) 4 (RW) pv1_hop2_temp_recipe_value,D111[...]

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 blende rs error checking, you m ust also ensure that you are in the correct recipe_entry_mode! SEE BELOW FOR DETAILS) RECIPE BOOK MANIPULAT ION 1 (RW) recipe_book_number, D2088, S HORT VALU E (select stor[...]

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 values are shown below: D1876 Value Alarm [...]

WRITING RECIPE EXPLANA TION To write a recipe you must first write to the “temp r ecipe” 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 reci pe enabled” is high then show a[...]

7-6 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [810] 720-7300; Fax [ 810] 720-2598 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 as sist i[...]