Gravimetric Slide Gate Batch Blender
Mitsubishi Controller
Part Number: 882.00273.00
Bulletin Number: BF1-615.3
Effective: 11/07/07
Write Down Your Serial Numbers Here For Future Reference:
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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 2007
All rights reserved.
Credit Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00
minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A
RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
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iii
Table of Contents
How to Use This Manual .............................................................................................7
Safety Symbols Used in this Manual.....................................................................7
Warnings and Precautions ..........................................................................................9
Responsibility ............................................................................................................10
Operator Responsibility.......................................................................................10
Models Covered in This Manual................................................................................13
General Description...................................................................................................13
Accessories.........................................................................................................13
Customer Service................................................................................................13
Typical Features and Components ...........................................................................15
Mechanical Features...........................................................................................15
System Component Description..........................................................................16
Supply Hoppers ...................................................................................................16
Slide Gates...........................................................................................................17
Weigh Hopper......................................................................................................18
Mix Chamber.......................................................................................................20
Operator Control Panel Display...........................................................................20
Optional Components................................................................................................25
Low Level Sensors..............................................................................................25
Regrind Auger Metering (R.A.M.) Hopper ...........................................................26
Safety Features.........................................................................................................27
Safety Device Lock-Outs.....................................................................................27
Uncrating the Equipment...........................................................................................30
Mechanical Installation..............................................................................................30
Site Requirements...............................................................................................31
Machine Mount....................................................................................................31
Mezzanine Mount ................................................................................................32
Floor Mount (Central Blender)............................................................................33
Electrical Connections...............................................................................................34
Pneumatic Connections ............................................................................................34
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Initial Set-up ..............................................................................................................35
Stroke Limiters for Metering Gates.....................................................................35
Weigh Hopper Installation...................................................................................36
Final Connections ................................................................................................36
Blender Controller Menu Structure .....................................................................38
Blender Calibration..............................................................................................39
Alarm Setup.........................................................................................................41
Network Setup .....................................................................................................42
Setting Date and Time .........................................................................................42
Additional Setup Parameters ...............................................................................43
Initial Startup .............................................................................................................44
Start-up......................................................................................................................45
General Operation...............................................................................................45
Quick Start Procedure.........................................................................................45
New Recipes ........................................................................................................45
Existing Recipes ..................................................................................................46
Operation Procedures ...............................................................................................46
Recipe Setup.......................................................................................................52
Feeder Clean Out................................................................................................59
Recipe Book........................................................................................................60
Shut-down .................................................................................................................63
Preventative Maintenance Schedule.........................................................................64
Preventative Maintenance.........................................................................................65
Corrective Maintenance ............................................................................................65
Introduction................................................................................................................67
Technical Specifications............................................................................................72
Annex B Information............................................................................................73
Drawings and Diagrams............................................................................................74
Final Assembly....................................................................................................74
Hopper Sub-assembly.........................................................................................77
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Slide Gate Sub-assembly....................................................................................81
Knife Gate Sub-assembly HD (Optional).............................................................82
Knife Gate Sub-assembly RD (Optional).............................................................83
Control Panel Layout...........................................................................................84
Spare Parts Kits ........................................................................................................85
Addendum (Service Supervisor Information) ............................................................86
Programmable Settings.......................................................................................86
Factory Setup Menu............................................................................................87
Mitsubishi Communications Manual..........................................................................94
Technical Assistance...............................................................................................101
Contract Department.........................................................................................101
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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, pre-
operational 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.
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Figure 1: Safety Tags and Warning Labels
Tag
Description
Tag
Description
Read Operation &
Installation Manual
Pinch Point Slide Gate
Shear Point Rotating
Mixer
Earth Ground
High Voltage Inside
Enclosure
Protected Earth Ground
Lifting Point
PE
Shear Hazard Rotating
Auger
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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.
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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.
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Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.
REMEMBER:
• NEVER place your hands or any part of your body in any dangerous location.
• NEVER operate, service, or adjust the blender without appropriate training and first
reading and understanding this manual.
• NEVER try to pull material out of the blender with your hands while it is running!
Before you start the blender check the following:
• Remove all tools from the unit;
• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the metering or
mixing area;
Note: If your blender has been inoperative or unattended, check all settings
before starting the unit.
Note: At the beginning of your shift and after breaks, verify that the controls
and other auxiliary equipment are functioning properly.
Note: Keep all safety guards in place and in good repair. NEVER attempt to
bypass, modify, or remove safety guards. Such alteration is not only
unsafe, but will void the warranty on your equipment.
Note: When changing control settings to perform a different mode of
operation, be sure selector switches are correctly positioned. Locking
selector switches should only be adjusted by authorized personnel and
the keys removed after setting.
Report the following occurrences IMMEDIATELY:
• unsafe operation or condition
• unusual blender action
• leakage
• improper maintenance
Note: NEVER stand or sit where you could slip or stumble into the blender
while working on it.
Note: DO NOT wear loose clothing or jewelry, which can be caught while
working on an blender. In addition, cover or tie back long hair.
Note: Clean the blender and surrounding area DAILY, and inspect the
machine for loose, missing or broken parts.
Note: Shut off power to the blender when it is not in use. Turn the switch to
the OFF position, or unplug it from the power source.
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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.
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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.
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Figure 2: Equipment Specifications
Dimensions and Specifications
150
500
500 (227)
2 to 6
900
2500
4000
6000
Maximum Blending Rate, lbs/hr (kgs/hr) (3)
150 (68)
2 to 4
900 (410)
2500 (1135) 4000 (1815) 6000 (2725)
2 to 8
Number of Materials to be Blended
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.)
2.0 (50)
1.5 (38)
0.7 (20)
0.2 (5)
2.0 (50)
2.5 (63)
2.0 (50)
4.0 (102)
3.0 (76)
1.5 (38)
2.5 (70)
1.8 (50)
5.2 (145)
3.6 (100)
0.82 (23)
25 (11.3)
2 @ 10 kg
1.1 (31)
14.3 (400)
10.2 (285)
0.07 (2)
1.5 (0.7)
1 @ 5 kg
0.18 (5)
1/8 (0.09)
42
0.18 (5)
0.38 (11)
8 (3.6)
1.23 (34)
2.17 (61)
45 (20.4)
2 @ 20 kg
Typical Batch Size, lbs. (kgs)
4 (1.8)
2 @ 3 kg
0.25 (7)
35 (15.8)
Load Cell Capacity, kgs
Mixer Capacity, cu.ft. (l.)
2 @ 5kg
0.56 (16)
2 @ 15 kg
2.72 (77)
Mixer Motor Size, HP (kw)
1/6 (0.124)
1/3 (0.248)
22
Mixer RPM
21
Blended Material Discharge Opening, in. (mm)
Weight of Machine (approx.), lbs. (kgs)
Shipping Weight (approx.), lbs. (kgs)
2.5 (63)
250 (115)
350 (160)
3.0 (76.2)
4.0 (102)
375 (170)
475 (215)
450 (205)
550 (250)
650 (295)
800 (360)
1100 (500)
1300 (590)
Approximate Dimensions, in. (mm)
Height (5)
Width (5)
Depth (5)
34.5 (875) 51.5 (1308) 56.5 (1435) 69.5 (1765) 85.5 (2172) 89.5 (2273)
26.0 (650) 37.5 (952)
37.0 (940) 45.5 (1156)
57.5 (1461)
57.0 (1448)
22.0 (560) 37.0 (940) 40.0 (1016) 46.5 (1181)
(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.
(3) See page 2 for important rate information concerning each model's maximum blending rate.
(4) Hopper capacity measured as level full volume. Capacity reduced when loaded automatically.
(5) Measurements describe standard unit without feeder or R.A.M. hoppers.
Figure 3: Typical Blender Assembly
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2-3 Typical Features and Components
Mechanical Features
• Exclusive diamond design slide gate metering assemblies meter a large range for free
flowing pellet materials
• Adjustable Slide gate stroke limiting restrictors provided for accurate metering of
minor ingredients (not on 150#)
• Removable Stainless steel weigh hopper and mixing components
• Powder Coated Mild steel material supply hoppers with machined polycarbonate
clean-out doors and optional material drains (stainless steel on 150#)
• Precision 1/10% span accurate cantilever load cell weighing system
• Interlocked safety system shuts off compressed air and electricity if mixer is opened
• Compressed air hose with nozzle for clean-out
Figure 4: Typical Mitsubishi Controller Touch Screen Display
Note: The touch-screen panel display on your unit may be slightly different
than shown.
Controller Features
• LCD touch-screen interface display operator control panel with 32’ cable
• Target vs. actual set point verification
• Inventory accumulation for all ingredients
• Audible and visual alarms
• Auxiliary alarm contact
• 50 recipe storage book
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• Three (3) types of recipe entry procedures available:
o
o
o
Quickset mode (up to 6-component) recipe entry. Color and additives are
metered as a percentage of the virgin material.
Percentage mode recipe entry. Ingredients are metered as a percentage of
the overall batch.
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 low-
level sensors are available. The blender controller will alarm if it runs out of material while
trying to make a batch, but low-level sensors will alert floor personnel to the problem sooner.
Each hopper is equipped with a sight glass and/or access door.
Figure 5: Typical Hopper Assembly
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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
DIAMOND GATE OPEN
regardless of the stroke
length of the cylinder.
This design provides a
wider cross sectional
DIAMOND GATE 1/2 CLOSED
opening when
approaching a closed
position, and provides
better flow of plastic
pellets out of the
DIAMOND GATE 3/4 CLOSED
opening.
DIAMOND GATE CLOSED
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 are controlled
by the blender controller.
When the solenoid valve is energized, it opens the metering valve cylinder. When the
solenoid valve is de-energized, it closes the metering valve cylinder.
If the power is interrupted to the blender, the metering valves will return to the closed
position, to prevent material from over-filling the weigh hopper/mix chamber.
Note: If the blender is in metering mode with one of the slide gates open, do
not open the front door of the blender!
Note: The safety switch shuts off the air supply to the blender. An open feeder
slide gate stays open, and an overflow of the weigh hopper can occur!
Weigh Hopper
The weigh hopper on the Slide Gate/Auger blender is used to weigh each batch of material,
and includes an air-operated discharge valve. After the batch is weighed and the level sensor
in the lower mix section is uncovered, the valve will open and discharge the batch into the
mixer with the existing blended material. The discharge valve is also provided with a quick
disconnect so the weigh hopper can be removed for cleaning.
On a Slide Gate blender, the weigh hopper rests on each side on a precision cantilever load
cell. To remove the weigh hopper, lift the hopper from the bottom, hold the dump door
closed, and slide it out once clear of the locating tab on the bracket above the load cell.
Once the hopper has been cleaned, reposition it onto the load cell brackets, using care not to
damage the load cells. Position the hopper as close to the center position between the load
cells as possible.
Note: Use care when replacing the weigh hopper, since the load cells are
delicate weighing instruments and can be easily damaged. Do not use
force to push in the weigh hopper. If it is positioned properly, it will slide
in very easily.
Note: Load cells, if damaged, will have to be sent back to the manufacturer for
testing and evaluation.
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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 it is desired to have a local display and control of the blender closer to a remote operator
station, an optional remote mount operator panel is available.
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Figure 9: Typical Mitsubishi Controller Touch Screen Display
Note: The touch-screen panel display on your unit may be slightly different
than shown.
Figure 10: Controller Pushbuttons & Touchscreen Tags
Button
Function
Turns power on to the blender controller.
(Found on the back of the controller.)
(Power On)
(Power Off)
Turns power off to the blender controller.
(Found on the back of the controller.)
Stops blender & restarts controller.
Press to move back one screen level in
controller function.
Move forward one screen level in controller
function.
Start (or stop) blender with current program
parameters.
Can erase current settings for one recipe or all
recipes.
Stops blender operation after current
inventory shutdown (if used) is completed
(This screen will be displayed.)
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Figure 11: Typical Operator Screens
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Figure 12: Typical Setup Screens
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2-4 Optional Components
The following is a list of options, which your blender may have been equipped with:
Pneumatic Slide Gate below Mixer
The Slide Gate/Auger blending system can be equipped with an optional pneumatic slide gate
below the mixing chamber. The gate is used in applications when the blender is mounted
above a large hopper, or for gaylord filling, etc. This gate holds the material in the mixing
section, to ensure that it is properly mixed. Control of the mixer function is described below,
and is determined by the position of the “knife gate switch” located on the side of the back
control panel.
WARNING! Slide gates create a pinch-point hazard.
Figure 13: Mixer Slide Gate Switch Positions
Position
AUTO
Description
Slide gate functions are automatically controlled by the blender
controller
OPEN
Slide gate open all the time
Slide gate closed all the time
CLOSE
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)
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Regrind Auger Metering (R.A.M.) Hopper
Used for feeding difficult regrind materials.
Figure 15: Typical R.A.M. Hopper Blender Configuration
Additive Feeder Hopper
Used for feeding pelletized additive, typically used on blenders with more than six
components.
Figure 16: Typical Additive Feeder Configuration
Take-off Compartments
Allows material to be metered into a vacuum conveying system.
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2-5 Safety Features
This section includes information on safety devices and procedures that are inherent to the
Gravimetric Batch Blender. This manual is not intended to supersede or alter safety standards
established by the user of this equipment. Instead, the material contained in this section is
recommended to supplement these procedures in order to provide a safer working
environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
• Identify and locate specific safety devices.
• Understand the proper use of the safety devices provided.
• Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and maintenance personnel
from dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the Slide
Gate/Auger Blender; however, it is the responsibility of the personnel operating and
maintaining the equipment to familiarize themselves with the safety procedures and the
proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue. For
example, if a safety switch is guarding a motor, and the safety switch fails, the motor should
not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used on the Slide Gate/Auger Blenders are primarily concerned with pneumatic and electrical
power disconnection and the disabling of moving parts that may need to be accessed during
the normal operation of the machine.
Some of the safety devices utilize a manual activator. This is the method of initiating the
safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable
handle, there may be a location for a padlock. Personnel servicing the equipment should
place a padlock in the lockout handle.
In addition to the safety devices listed above, these blenders are equipped with a line cord
plug (Shown in figures 17 and 18). This allows the operator or maintenance personnel to
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unplug the unit from its power source and tag it out. The plug can then be tagged with any
number of approved electrical lockout tags available at most electrical supply stores.
Figure 17: Electrical Disconnect Plug
Twist Cap Plug Connected to Each Feeder Auger Motor
The cap plug must be turned counter-clockwise to loosen and the female end of the cord
removed from the motor plug. This disables the motor from turning while the auger unit is
being serviced or cleaned. The motor cords are cut to length so they must be disconnected
before the auger can be removed from the housing. Disconnect plug before cleaning or
servicing motors or augers.
Figure 18: Twist Cap Plug
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.
Note: 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 pre-drilled 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.
Take care to insure proper orientation with adequate access to operator controls, mix
chamber, and metering units.
Note: 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
MEZZANINE (SUPPLIED BY
CUSTOMER)
EXTRUSION CONTROL UNIT WITH
RE-LOAD VALVE
(PURCHASED SEPARATELY)
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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 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.
Note: 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.
Make sure that the blender location is adequately away from high traffic aisles, and that fork
trucks, etc. cannot damage the blender. Ensure 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.
Note: 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: As this blender uses air for blender metering functions, 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 provided by the customer 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
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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 ASSEMBLY MUST HANG FREELY AND BE
FREE FROM FRICTION, WITH NO MECHANICAL
OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF.
Final Connections
Connect the blender to the appropriate power source.
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.
Note: Again, make sure that proper air supply connections are made to the
blender, as dirty, contaminated, wet air can damage blender components
eand 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 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 Screen (Next Screen in sequence). The software versions are also
available on the Panel View Configuration Screen.
Figure 27: Display Main (Recipe) Screen
New Recipe
Input
Recipe Entry Mode
Mixer Status
Feeder Type
Indicator
Start/Stop
Blender
Go To Inventory
Screen
Immediately
Stop Blender
Go To Recipe
Book
Accept New Recipe
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
“Recipe” Page” (Start)
“Recipe Book” Page
Recipe Format
¾
¾
¾
Change Recipe Values by
touching the number you
wish to change
Touch “Accept New Recipe”
button after you’ve made
the desired changes
Start or stop the blender by
touching the “Push to Start”
or “Stop” button
¾
Save the running recipe to
the book
¾
Percentage, Parts, or Quick
Set
¾
¾
¾
¾
Delete a stored recipe
Load a stored recipe
Erase all stored recipes
Modify the product ID for a
stored recipe
¾
¾
¾
¾
Batch Size
Inventory Shutdown
“Batch ready” mode
“Auto start” mode
¾
Return to the “Recipe” page
¾
¾
¾
¾
Access “Recipe Book” Page
Access “Clean Out” Page
Access “Inventory Page”
Access “Setup” Page
Report Setup
¾
¾
¾
¾
Blender Number
“Auto clear” option
“Auto interval” setup
Auto start time
“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
View and test all inputs and
outputs on the blender
¾
¾
Calibration
Return to the “Recipe” Page
¾
¾
¾
Scale Calibration
Direct Scale Readout
Feeder Calibration
“Inventory” Page
¾
View the accumulated
inventories
Mixer and Dump Setup
¾
¾
View batch time
View blender’s maximum
capacity
View the average process
rate
¾
¾
¾
¾
¾
¾
¾
Mixing Time
Remix Time
Dump Time
Dump Delay
Dump Cycles
Mixer Dump Time
Timed/Continuous Mixing
Option
¾
¾
Return to the “Recipe”
F940 “Config”
¾
¾
View software version
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.)
“Setup” Page
Login from the inventory
¾
page by hitting “Login” and
entering in your password.
Then access setup by
Alarm Log
¾
View and clear the alarm log
touching the Sterling Logo.
Alarm Setup
¾
¾
¾
“Stop/Continue” when out of
material
“Alarm/No Alarm” when out of
material
“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 provided 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,
although 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
Enter in the Calibration
Weight
Current Loadcell
Bits
Press here to perform
the calibration
Follow
Instructions
Go Back to the
Calibration Directory
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”.
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 removing the weigh hopper during clean out.)
7. Press “Done” until you have reached the Recipe screen.
8. ***Anything in the Diagnostics Menu that is not covered here is in the Detailed
Controller Setup Section***
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 continue. It stops on that component continuing to try and meter. The optional low level
proximity switches have their own separate alarm. The alarm will sound, but does not stop
the blender. To 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
Enable or Disable
Retries
Select a Feeder to
Configure
Enable or Disable
Alarms
Change the Alarm
Silence Delay
Go back to Setup
Directory
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3. Select a feeder (1-6) by touching the “Select Feeder” box.
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 blenders 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 related button and choosing the correct number.
Figure 32: PanelView Configuration Screen
Go back to
Setup Directory
Press to set
Date & Time
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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 lose 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 in progress is first finished 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). 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: Hopper #3 on some models 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 hit 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 and the recipe will be entered.
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Note: The blender monitors the operator’s entries and determines 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 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.
Note: 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 hit 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.
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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.
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 trouble shooting 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
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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 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, 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.
Note: 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
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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 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.
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“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. 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 the operator will
know what material is being blended.
Note: The #1 hopper (“NAT” - Virgin Material) recipe ingredient will not be
shown on the recipe setup menu.
Note: ADD (Additive) designations will weigh the ingredient as a percentage of
natural material only.
Note: 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.)
Note: Virgin material must be loaded into hopper #1 and regrind into hopper
#3.
Note: 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):
Regrind (RGD):
Additive2 (ADD):
Additive3 (ADD):
5.00% - of virgin component
30.00% - of total batch
2.00% - of virgin component
1.00% - of virgin component
Batch Size:
Total available:
Regrind:
10.00 lbs.
100.00%
30.00%
70.00%
Balance:
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.
“Parts” Mode (Often used in 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: Hop 1=300 parts, Hop 2=100 parts, Hop 3=10 parts, Hop 4=5
parts. This would mean that if the batch was divided into 415 parts, then Hop 1 would make
up 300 of those parts, Hop 2 would make up 100, Hop 3 10 parts, and Hop 4 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
Calculated Weight
Feeder Tag
Preset Part
(Ratio Control)
7,200/10,000
Virgin
Regrind
Color
Additive
Total:
#1
#2
#3
#4
7,200
2,000
500
300
10,000
2,000/10,000
500/10,000
300/10,000
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 to 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
500
1.5
4.0
900
8.0
2500
4000
6000
25.0
35.0
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 if you don’t
want to make another
batch
Touch to make
another box of
material
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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
continuously, 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
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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 mixing 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 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 totally 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.
Figure 41: 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.
Figure 42: Typical “Maximum Hopper Weight” Alarm Screen
MAX HOPPER WEIGHT
EXCEEDED
check batch size
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.
Figure 43: 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.
Figure 44: 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.
Figure 45: 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 can not 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
hitting the E-Stop.
Figure 46: 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 on power 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 47: Typical Manual Control Operator Screen
Test Alarm
Output
Empty Entire
Blender
Open or Close
Feeder
Warning Message
Open or Close
Weigh Hopper
Current Hopper
Weight
Start or Stop Mixer
Motor
Go back to Setup
Directory
Open or Close
Mixer Knife Gate
Low Level Prox
Status
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 and 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
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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.
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 to 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 be 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 48: Typical Recipe Book Operator Screen
Erase One
Stored Recipe
Select a Stored
Recipe
Erase Entire
Book
Stored Recipe
Details
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.
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:
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, as 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
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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 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.
WARNING!
Always disconnect the air supply to the blender.
WARNING! Prior to performing any operations inside any access areas of the blender
where there are moving parts.
6. 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.
WARNING! 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.
7. 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.
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8. 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.
9. 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
hoppers above them have been drained.
10. Clean the weigh hopper and mixer assemblies on the blender using a vacuum cleaner.
The mixer agitator is removable for cleaning if desired.
11. Reinstall any metering units that were removed from the blender during clean out.
12. Reinstall the weigh hopper using care to center the hopper on the load cells on the
weigh hopper bracket.
13. Load the blender with new material.
14. Restart the unit with the new recipe.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e.
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.
4-3 Shut-down
The Slide Gate Gravimetric Blender can be stopped in one of two ways:
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 the operator desires to complete the current batch of material, then he 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 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 49: Typical Inventory Shutdown Operator Screen
Touch if you don’t
want to make another
batch
Touch to make
another box of
material
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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 50: Sample Preventative Maintenance Schedule
System model #
Serial #
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
Daily
By
By
By
By
By
By
By
By
By
By
By
By
By
Inspect blender for
any loose parts-
tighten them
immediately.
Verify quality of
compressed air
supply.
Verify mixer door is
properly latched.
Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/ Date/
By By By By By By By By By By By By By
Every week
Inspect metering
gates for proper
operation.
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
insure 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.
Note: This contact is for use with a customer supplied alarm device as
described above.
Note: 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 trouble-shooting 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 over-emphasized 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-per-volt 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 51: 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
Check the E-Stop located on the front of the blender panel.
Click “Unlock” and enter in your User Password.
Contact the Service Department.
“Interface has been Locked” is
shown
I’ve forgotten my User
Password
POWER INTERRUPTION
ALARM
Power was lost during a batch. Check your power source unless
you intentionally killed the power during the batch.
Change out the PLC with your spare and reprogram new unit.
Send old PLC back to manufacturer for repair.
PLC Battery Low
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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
blender will automatically restart.
PLC Module Loaded
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 has not lodged under a load cell.
Weigh hopper occasionally
overfills.
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
time until the problem is corrected.
Material tends to separate in the
mixing chamber.
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.
Material sticks to the flapper of
the weigh hopper and is not
dumped.
Increase the Dump Cycles setting in Mixer and Dump Setup.
Too much material remains in
the mixer.
Increase the Mixer Dump Time in Mixer and Dump Setup.
Increase the Mixing Time in Mixer and Dump Setup. Actually 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.
The material is not being mixed
thoroughly.
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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 Totals don’t
match what I’ve actually used
Some error can be introduced by not weighing every batch. Check
the Recipe Page.
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.
Max Hopper Weight Exceeded
Alarm continues to re-occur.
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.
Blender occasionally dumps an
incorrect batch.
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).
Blender keeps dumping after
mixer is full.
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.
Check the proximity switch connection.
Make sure that the recipe is correct.
Check batch size.
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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
a calibration weight on the weigh hopper; determine if the weight
corresponds.
Mixer won’t shut off and runs
continuously.
Check the load cells to make sure that a pellet has 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; 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.
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”.
Out of Material Alarm is
displayed, but there is material
in the hopper.
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).
I’m not getting Out of Material
Alarms
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 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.
Calibration Weight Exceeded
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.
The feeder calibration values
are moving too much.
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Problem
Corrective action
This Is caused by the difference in bits not being large enough.
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.
I can’t calibrate the Scale
without an error message.
Do other feeders calibrate correctly? Is the feeder I’m trying to
calibrate a large gate? If these are true, then lower the Batch % for
Feeder Cal setting under Feed Calibration Options. This can be
observed by looking at the Hopper Weight display.
I can’t calibrate the feeder
without an error message.
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.
Weigh hopper does not empty
completely.
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.
Verify additive percentage is not higher than designed, resulting in
excessive dispense time.
Blender does not make rate.
Verify all materials are feeding freely through the metering gates
or augers.
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.
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.
A feeder always puts too much
material in the batch.
Increase the Gate Cycle Time. This is found under Feed
Algorithm Options. Make small adjustments and retest.
A feeder is retrying more than
2-4 times.
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.
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Chapter 7: Appendix
7-1 Technical Specifications
Equipment Specifications
Figure 52: Equipment Specifications
Dimensions and Specifications
150
500
500 (227)
2 to 6
900
2500
4000
6000
Maximum Blending Rate, lbs/hr (kgs/hr) (3)
150 (68)
2 to 4
900 (410)
2500 (1135) 4000 (1815) 6000 (2725)
2 to 8
Number of Materials to be Blended
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.)
2.0 (50)
1.5 (38)
0.7 (20)
0.2 (5)
2.0 (50)
2.5 (63)
2.0 (50)
4.0 (102)
3.0 (76)
1.5 (38)
2.5 (70)
1.8 (50)
5.2 (145)
3.6 (100)
0.82 (23)
25 (11.3)
2 @ 10 kg
1.1 (31)
14.3 (400)
10.2 (285)
0.07 (2)
1.5 (0.7)
1 @ 5 kg
0.18 (5)
1/8 (0.09)
42
0.18 (5)
0.38 (11)
8 (3.6)
1.23 (34)
2.17 (61)
45 (20.4)
2 @ 20 kg
Typical Batch Size, lbs. (kgs)
4 (1.8)
2 @ 3 kg
0.25 (7)
35 (15.8)
Load Cell Capacity, kgs
Mixer Capacity, cu.ft. (l.)
2 @ 5kg
0.56 (16)
2 @ 15 kg
2.72 (77)
Mixer Motor Size, HP (kw)
1/6 (0.124)
1/3 (0.248)
22
Mixer RPM
21
Blended Material Discharge Opening, in. (mm)
Weight of Machine (approx.), lbs. (kgs)
Shipping Weight (approx.), lbs. (kgs)
2.5 (63)
250 (115)
350 (160)
3.0 (76.2)
4.0 (102)
375 (170)
475 (215)
450 (205)
550 (250)
650 (295)
800 (360)
1100 (500)
1300 (590)
Approximate Dimensions, in. (mm)
Height (5)
Width (5)
Depth (5)
34.5 (875) 51.5 (1308) 56.5 (1435) 69.5 (1765) 85.5 (2172) 89.5 (2273)
26.0 (650) 37.5 (952)
37.0 (940) 45.5 (1156)
57.5 (1461)
57.0 (1448)
22.0 (560) 37.0 (940) 40.0 (1016) 46.5 (1181)
(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.
(3) See page 2 for important rate information concerning each model's maximum blending rate.
(4) Hopper capacity measured as level full volume. Capacity reduced when loaded automatically.
(5) Measurements describe standard unit without feeder or R.A.M. hoppers.
BF1-615.3
Chapter 7: 6BAppendix
72 of 101
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:
Fahrenheit)
40 degrees Celsius – Maximum (104 degrees
3. Humidity range:
4. Altitude:
50% relative humidity
Sea level
5. Environment:
6. Radiation:
Clean, dust-free and non-explosive
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. Allowable frequency fluctuation: Continuous
Intermittent
+/- 10%
+/- 1%
+/- 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:
13. Earth ground type:
120/1/60 or 220/1/50/60 (Verify on serial number tag)
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.
BF1-615.3
Chapter 7: 6BAppendix
73 of 101
7-2 Drawings and Diagrams
Final Assembly
Figure 53: Typical Final Assembly Parts List
#
1
Description
Mixer Assembly
150
A0771677
N/A
N/A
CTB01648
CTB02248
900
A0771683
2500
4000
6000
A0771682
A0771663 A0771691 A0771692
3-Component Hopper Assembly
2-Component Hopper Assembly
Removable Hopper Small
Removable Hopper Large
Slide Gate Assembly – Majors
Slide Gate Assembly – Minors
Valve Stack Assembly 4-Comp
Valve Stack Assembly 6-Comp
Main Controller
A0771687
A0771686
A0771664
A0771665
N/A
N/A
A0771660
A0771661
A0771700
A0771699
2
A0771661
A0771680
A0770375
A0770376
A0771701
A0771708
N/A
N/A
3
4
A0569133
A0569134
5
6
7
8
9
Main Display (Not Shown)
Calibration Weight (Not Shown)
Hopper Support Straps
A0574219
822.00334.00 822.00151.00 822.00152.00 A0571769
N/A A0569157
A0567625
822.00153.00
872.00246.00
Louvers – Hopper Covers
N/A
BF1-615.3
Chapter 7: 6BAppendix
74 of 101
Figure 54: Typical Mixer Assembly Parts List
#
1
2
DESCRIPTION
FRAME
500
872.00093.00 872.00094.00
N/A
900
2500
A0770301
4000
872.00224.00
872.00225.00
872.00226.00
6000
FRAME EXTENSION (NOT SHOWN)
TOP PLATE
872.00095.00 872.00096.00
A0770300
A0770333
3
MOUNTING BRACKET – MIXER
MOTOR
872.00097.00 872.00098.00
A0770316
872.00227.00
A0770318
872.00228.00
4
MIX CHAMBER BACK PLATE
COUPLING – AGITATOR DRIVE
AGITATOR – MIXING
872.00099.00 872.00100.00
832.00010.00
5
6
7
8
9
872.00101.00 872.00102.00
832.00011.00
A0574115
A0770320
A0770319
DRAWER SUPPORT
832.00034.00
21063
BUSHING – AGITATOR
832.00012.00
724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00
LOADCELL (TWO)
10
11
MOUNTING BRACKET – WEIGH
HOPPPER
A0770313
A0770322
COVER GUARD – LOADCELL
WEIGH HOPPER
12
13
14
15
16
17
872.00103.00 872.00104.00
872.00105.00 872.00106.00
872.00107.00 872.00108.00
832.00013.00 832.00014.00
A0770312
A0770314
A0770315
A0770303
09990
872.00229.00 872.00230.00
872.00231.00
STOP RAIL – MIXER DRAWER
MIXER DRAWER
872.00232.00
ACCESS DOOR – MIXER
DOOR CLIPS
832.00035.00 832.00036.00
SAFETY COVER – MIXER FRONT
(NOT SHOWN)
872.00109.00
N/A
18
DOOR LATCH
35454
19
20
21
SUPPORT BRACE – MIXER DOOR
SAFETY COVER – MIXER BACK
N/A
872.00110.00
A0770332
A0770302
872.00233.00
872.00234.00
872.00111.00 872.00112.00
MOUNTING BRACKET – CONTROL
PANEL (NOT SHOWN)
PROXIMITY SENSOR – MIXER
HIGH-LEVEL
E-STOP SAFETY DISCONNECT
SWITCH
872.00124.00
N/A
22
23
24
25
A0556548
64269
SAFETY DISCONNECT SWITCH –
MIXER DOOR
A0567124
GEAR MOTOR
720.00001.00
720.00002.00
26
27
FLOW VALVE 1/4" TUBING
A0770190
BF1-615.3
Chapter 7: 6BAppendix
76 of 101
Hopper Sub-assembly
Figure 55: Typical Hopper Assembly Parts List
#
1
DESCRIPTION
500
872.00118.00
872.00119.00
900
2500
4000
872.00240.00
872.00241.00
6000
3-COMPONENT HOPPER
2-COMPONENT HOPPER
LEXAN DOOR
DOOR LATCH
3.5” SIGHT GLASS
4.5” SIGHT GLASS
(OPTIONAL) 2” DRAIN W/ MANUAL
GATE (NOT SHOWN)
(OPTIONAL) 3” DRAIN W/ MANUAL
GATE (NOT SHOWN)
A0569131
A0770299
A0770286
A0770076
3
4
5
6
A0569154
A0569162
N/A
N/A
N/A
A0770323
N/A
7
A0569163
(OPTIONAL) BRACKET - LOW-LEVEL
SENSOR (NOT SHOWN)
(OPTIONAL) PROXIMITY SENSOR
LOW-LEVEL (NOT SHOWN)
A0569155
A0556548
8
9
BF1-615.3
Chapter 7: 6BAppendix
77 of 101
Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional)
Figure 56: Typical R.A.M. Hopper Assembly Parts List
#
1
2
3
4
5
6
7
8
9
DESCRIPTION
THROAT
CLAMP
FEEDER TUBE
500
900
2500
07822-1
A0548808
872.00426.00
08806A-HYD
08806B
08451
55372
720.00004.00
872.00421.00
4000
6000
#
#
#
DRAIN HOUSING
DRAIN SLIDE GATE
MOTOR MOUNT BRACKET
SEAL – AUGER - TEFLON
MOTOR - AUGER
AUGER
#
HOPPER 2.0 CU.FT.
HOPPER 7.0 CU.FT.
DOOR
872.00417.00
N/A
N/A
872.00418.00
10
A0770286
A0770076
A0567124
11
12
13
14
15
16
17
18
19
20
21
LATCH
SAFETY INTERLOCK SWITCH
BRACKET – SAFETY SWITCH
SIGHTGLASS 4.5”
MOTOR – AGITATOR
AGITATOR
SEAL – AGITATOR - RUBBER
RECEPTACLE – 3-PIN FEMALE
CORD 3-PIN MALE 6 FT LONG
STEADY STATE RELAY – 10 AMP
GLASS FUSE – 3.0 AMP (115V UNIT)
GLASS FUSE – 1.5 AMP (230V UNIT)
872.00431.00
A0770323
51489
10637
15286
63119
55196
729.00183.00
A0542207
A0542200
22
BF1-615.3
Chapter 7: 6BAppendix
78 of 101
Hopper Additive Feeder Sub-Assembly (Optional)
Figure 57: Typical Additive Feeder Hopper Assembly Parts List
#
1
2
3
4
DESCRIPTION
THROAT
MOTOR MOUNT BRACKET
MOTOR – AUGER
THROAT ADAPTER – 2” RISER
HOPPER 1.0 CU.FT.
500
900
2500
4000
6000
A0541201
A0541229
51450G
872.00537.00
A0541207
N/A
N/A
N/A
5
HOPPER 2.0 CU.FT.
A0541208
SIGHTGLASS – AF
A0541206
A0541215
A0541216
6
7
8
COVER PLATE – HOPPER CLEANOUT
COVER PLATE – SAMPLE PORT
TRANSFER TUBE – 1” AUGER
AUGER ASSEMBLY – 1” AUGER
COUPLING – MOTOR/AUGER
PIN – MOTOR MOUNT (NOT SHOWN)
RECEPTACLE – 3-PIN FEMALE
(NOT SHOWN)
CORD 3-PIN MALE 6 FT LONG
(NOT SHOWN)
STEADY STATE RELAY – 10 AMP
(NOT SHOWN)
A0541211
A0541294
#
#
9
10
11
12
A0541282
A0541277
63119
55196
13
14
15
729.00183.00
A0542207
GLASS FUSE – 3.0 AMP (115V UNIT)
(NOT SHOWN)
GLASS FUSE – 1.5 AMP (230V UNIT)
(NOT SHOWN)
16
A0542200
BF1-615.3
Chapter 7: 6BAppendix
79 of 101
Weigh Hopper Sub-assembly
Figure 58: Typical Weigh Hopper Assembly Parts List
#
1
2
DESCRIPTION
WEIGH HOPPER
AIR CYLINDER
CLEVIS – AIR
CYLINDER
FITTING – AIR
TUBING
AIR TUBING
(NOT SHOWN)
500
872.00103.00
900
872.00104.00
2500
A0770312
4000
872.00229.00
A0770248
6000
872.00230.00
245.00003.00
35460
35449
3
4
5
35086K
35085K
35300K
BF1-615.3
Chapter 7: 6BAppendix
80 of 101
Slide Gate Sub-assembly
Figure 59: Typical Slidegate Assembly Parts List
#
DESCRIPTION
500
900
2500
4000
6000
HOUSING (DOUBLE DIAMOND) (#1-4)
HOUSING (SQUARE / DIAMOND) (#1-4)
HOUSING (DOUBLE DIAMOND) (#5-6)
GATE – DIAMOND (#1-4)
GATE – SQUARE (#1-4) (NOT SHOWN)
GATE – DIAMOND (#5-6)
GUIDE ROD (#1-4)
GUIDE ROD (#5-6)
AIR CYLINDER (#1-4)
AIR CYLINDER (#5-6)
CLEVIS – AIR CYLINDER (#1-4)
CLEVIS – AIR CYLINDER (#5-6)
FITTINGS – AIR CYLINDER
STROKE LIMITER (#1-4)
STROKE LIMITER (#5-6)
QUICK RELIEF VALVES (NOT SHOWN)
872.00114.00
A0770304
N/A
A0770308
A0770305
N/A
A0770309
A0770307
A0770311
872.00524.00
1
A0770308
872.00113.00
A0770309
872.00116.00
872.00115.00
A0770311
832.00015.00
35448
872.00235.00
872.00237.00
872.00236.00
872.00237.00
2
832.00037.00
245.00016.00
A0770296
3
4
35448
35449
245.00006.00
35449
5
6
7
8
35460
A0770136
A0770306
A0770310
A0770310
82.00117.00
872.00238.00
245.00024.00
N/A
BF1-615.3
Chapter 7: 6BAppendix
81 of 101
Knife Gate Sub-assembly HD (Optional)
Figure 60: Typical Knife Gate (below mixer) Assembly Parts List
#
1
2
3
4
5
6
7
8
DESCRIPTION
BASE FRAME
MOLDED THROAT
SPACER PLATE
FLANGE ADAPTER
KNIFE BLADE
MOUNTING BRACKET – AIR CYLINDER
AIR CYLINDER
-
500
900
2500
07990
53413
08286
08292
10644
33088
33091
-
4000
6000
MOUNTING NUT – AIR CYLINDER
CLEVIS – AIR CYLINDER
BUSHING 1/4 - 1/8 NPT
ELBOW 1/8 NPT
SOLENOID 4-WAY 24VDC
FITTING – 1/8 NPT X 1/4 TUBE
MUFFLER 1/8 NPT FLUSH
FITTING – 1/4 NPT X 1/4 TUBE
SAFETY SHIELD
A0553239
33090
35014
35118
33128
35086K
35157
35154
A0770364
07990B
9
10
11
12
13
14
15
16
17
18
A0770362
A0770363
A0770365
STROKE LIMITER PIPE (NOT SHOWN)
BF1-615.3
Chapter 7: 6BAppendix
82 of 101
Knife Gate Sub-assembly RD (Optional)
Figure 61: Typical Knife Gate (floor stand) Assembly Parts List
#
1
2
3
4
5
6
7
8
DESCRIPTION
HOUSING FRAME
GUARD SAFETY COVER
ROD GUIDE
GATE – SLIDE BLADE
AIR CYLINDER
CLEVIS – AIR CYLINDER
NUT – LOCKING
FITTING ELBOW 1/8 NPT X 1/4 TUBE
NIPPLE 1/8 NPT
SOLENOID 4-WAY 24VDC
FITTING STRAIGHT 1/8 NPT X 1/4 TUBE
FITTING MUFFLER STONE 1/8 NPT
500
900
2500
4000
6000
872.00297.00
872.00236.00
832.00049.00
872.00236.00
245.00016.00
A0770296
A0533826
35086K
A0015494
33128
35085K
9
10
11
12
35157
BF1-615.3
Chapter 7: 6BAppendix
83 of 101
Control Panel Layout
Figure 62: Typical Mitsubishi Controller Main Parts List
#
1
2
3
4
5
6
Description
Mitsubishi PLC FX2N-32MR
Mitsubishi PLC EEPROM
150
500
900
2500
4000
6000
A0569702
A0569703
A0563932
724.00117.00
A0565889
A0542574
A0542200
A0540997
A0542207
A0542200
24 vdc Power Supply
Calex Module – Load Cell Amplifier
Alarm Light Yellow Strobe 24 vdc
Alarm Horn 95db 24vdc
Glass Fuse – 1.5 amp (115v unit)
Glass Fuse – 1.0 amp (230v unit)
Glass Fuse – 3.0 amp (115v unit)
Glass Fuse – 1.5 amp (230v unit)
Motor Contactor
Motor Overload – MCP (115v unit)
Motor Overload – MCP (230v unit)
Light Bulb – Power Switch (115v unit)
Light Bulb – Power Switch (230v unit)
Light Bulb – Safety Active 24vdc
Alarm Relay
5
6
7
8
A0573025 (9 amp)
A0573026 (12 amp)
A0558252 (1.6-2.5 amp)
A0558251 (1.0-1.6 amp)
A0558255 (6.3-10.0 amp)
A0558254 (4.0-6.3 amp)
A0544076
A0567108
A0565884
A0567058
9
10
11
Figure 63: Typical Mitsubishi Display Main Parts List
#
1
2
Description
Mitsubishi Pendant Touchscreen Display
Display – 32 ft Connection Cable
150
500
900
2500
4000
6000
A0569706
A0569705
BF1-615.3
Chapter 7: 6BAppendix
84 of 101
7-3 Spare Parts Kits
Figure 64: Blender Spare Parts Listing
Model
150
500
900
2500
4000
6000
KIT "A" (Consumables)
Load Cell Assembly (without plug)
Mixer High Level Sensor
(5) Fuses, 1.5 Amp
A0574120
A0574134
A0574137
A0574125
A0574140
A0574143
#
#
724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00
A0556548
(5) A0542200
(5) Fuses, 3.0 Amp
(5) A0542207
KIT "B" (Minimal Downtime)
All "A" Kit Parts
A0574121
A0574120
A0574135
A0574134
A0574138
A0574137
35448
A0574126
A0574125
A0574141
A0574140
245.00016.00
245.00016.00
A0770248
A0573026
A0574144
A0574143
Slide Gate Air Cylinder - Majors
Slide Gate Air Cylinder - Minors
Weigh Hopper Air Cylinder
Mixer Motor Contactor
#
#
#
245.00006.00
245.00003.00
A0573025
35448
Power Supply, 24vdc
Mixer Door Safety Switch
A0563932
A0567124 + A0567125
#
KIT "C" (24/7 Operation, or International)
All "A" and "B" Kit Parts
A0574122
A0574121
A0574136
A0574135
A0574139
A0574138
A0574127
A0574126
A0574142
A0574141
A0574145
A0574144
Second Load Cell Assembly (without plug)
Mixer Motor Protector (overload)
Calex Module
724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00
A0558252
A0558255
724.00117.00
Other Recommended Parts
Mixer Gear Motor
Mixer Agitator
150
#
#
N/A
#
N/A
500
900
2500
720.00002.00
4000
6000
720.00001.00
872.00101.00 872.00102.00 872.00225.00
832.00010.00
720.00002.00
872.00228.00
832.00030.00
A0771704 A0771705
Mixer Coupling
Weigh Hopper Assembly
Valve Stack Assembly
MIT Pendant Operator Touch Screen
MIT PLC CPU
A0771684
A0771685
A0771662
A0770132 (4-Component) -or- A0770144 (6-Component)
A0569706
A0569702
A0569703
MIT PLC EEPROM
One of each of these parts is recommended if you have MULTIPLE blenders and rely on long term, continous operation.
BF1-615.3
Chapter 7: 6BAppendix
85 of 101
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 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.
Caution!
After all selections are made: Keep pressing the “Done” key until the unit
returns to the Recipe menu.
Note: Programmable features should not be accessed by inexperienced
operators or inexperienced plant personnel. Unauthorized changes may
prevent the blender from operating properly and may void part or all of
the warranty.
Note: 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.
Note: Information included in this manual is subject to change without notice.
Passwords
• User Password
• Maintenance Password
“5413”
“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.
Figure 65: Typical Operator Setup Screen
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.
BF1-615.3
Chapter 7: 6BAppendix
86 of 101
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 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.
Figure 67: Typical Metering Test Screen
Select a Feeder
Stop the Meter
Change Method
Target Weight
Meter Data
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.
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Chapter 7: 6BAppendix
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This setting should not be modified except by the developer except under unusual
circumstances.
Figure 68: Typical Advanced Weight Options Screen
Adjust the limit
for “Hopper Over
Weight Filter
Max Weight”
Weight/Sec.
Filter
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.
Figure 69: 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.
Figure 70: Typical Feed Calibration Options Screen
Go back to
Engineering Only
Directory.
BF1-615.3
Chapter 7: 6BAppendix
88 of 101
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.
Figure 71: 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.
Figure 72: Typical Feeder Setup Screen
Go back to
Engineering Only
Directory.
BF1-615.3
Chapter 7: 6BAppendix
89 of 101
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.
Figure 73: Typical Units Screen
Change
Blender’s
Units
Change Target vs.
Actual 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.
Figure 74: Typical Ethernet Setup Screen
Enable or
Disable the
Ethernet
Go back to Setup
Directory
BF1-615.3
Chapter 7: 6BAppendix
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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. Hit “Done” to exit.
Figure 75: Typical Alarm Flags & Feeder Setup Screen
Select a Feeder to
Configure
Enable or Disable
Retries
Enable or Disable
Alarms
Go back to Setup
Directory
Change the Alarm
Silence Delay
Alarm Log
This screen shows the last 100 stored alarms. The log can be viewed, printed and cleared.
Figure 76: Typical Alarm Log Screen
Alarm Log
Clear Alarm
Log
Go back to
Setup
Directory
Print Alarm
Log
Scroll Through
Alarm Log
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Chapter 7: 6BAppendix
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Factory Default Setup Parameters
Model Number
150
500
900
2500
4000
6000
ALL WEIGHT VALUES RECORDED IN POUNDS
(DIVIDE BY 2.20462 FOR KILOGRAMS)
RECIPE FORMAT
Recipe Entry Mode
Metering Order
Batch Size (lbs)
PERCENTAGE
2.0
"EZ" MODE / "QUICK SET" MODE
12345678
4.0
8.0
25.0
35.0
45.0
Inventory Shutdown
Batch Ready Mode
AutoStart Mode
0
ENABLED
ENABLED
Weighing mode
EVERY BATCH
REPORT SETUP
Blender Number
1
Auto Print Inventory
Auto Clear Inventory
Auto Print/Clear Interval
Start Hour
DISABLED
DISABLED
8
0
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)
0.25
1.00
0.25
2.00
0.25
0.25
0.25
0.25
0.25
1.50
10.00
3.00
10.00
3.00
3.00
3.00
1.00
1.00
0.25
1.50
"Feeder Calibration wt/sec" values assume stroke limiters installed
in hoppers #2 & #4 & #5 thru #8
MIXER AND DUMP SETUP
Mixing Time
Remix Time
4
0
Dump Time
Dump Delay
Dump Cycles
Mixer Dump Time (w/o knifegate set to 0)
Continuous/Timed Mixing
1
1
2
2
4
0
1
6
4
TIMED
USER PASSWORD
User Password
5413
Maintenance Password
3145348
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 Material
Hop2 Alarm/No Alarm on Out of Material
Hop3 Alarm/No Alarm on Out of Material
Hop4 Alarm/No Alarm on Out of Material
Hop5 Alarm/No Alarm on Out of Material
Hop6 Alarm/No Alarm on Out of Material
Hop7 Alarm/No Alarm on Out of Material
Hop8 Alarm/No Alarm on Out of Material
NETWORK SETUP
STOP
STOP
STOP
STOP
STOP
STOP
STOP
STOP
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM
ALARM
Ethernet Configurator
ENABLED
IP Address
192.168.0.10
Subnet Mask
255.255.255.0
ADVANCED WEIGHT OPTIONS
Weight Filter
5
Max Tare Offset (lbs)
1
Wt/Sec Filter
1
% Above batch size for max weight
Time to settle hopper after batch dumped
Simulator
25
5
Simulator off
Don't Print Weight Data
Weight Data Printing
BF1-615.3
Chapter 7: 6BAppendix
92 of 101
Model Number
150
500
900
2500
4000
6000
ALL WEIGHT VALUES RECORDED IN POUNDS
(DIVIDE BY 2.20462 FOR KILOGRAMS)
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
99
100
100
99
99
99
99
99
99
99
98
98
98
98
98
98
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.015
0.004
0.015
0.004
0.004
0.004
0.004
0.004
5
0.03
0.01
0.03
0.01
0.01
0.01
0.01
0.01
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
10
10
Out of Material Retry limit before alarm
Batches for process rate
3
Process Rate Filter
"Initial Target %" and "Allowed Underfeed" values assume stroke limiters installed
in hoppers #2 & #4 & #5 thru #8
FEED CAL OPTIONS
25
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
10
10
10
25
25
25
10
10
10
10
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.05
0.10
0.10
0.05
0.05
0.10
0.05
0.05
0.05
0.05
0.05
3
3
3
3
3
3
Hop2 Settle Time
Hop3 Settle Time
Hop4 Settle Time
Hop5 Settle Time
Hop6 Settle Time
3
3
4
4
Hop7 Settle Time
Hop8 Settle Time
1 Loadcell
2 Loadcells
Loadcells
0.25
SEE ORDER
Mixer Bump Time to Detect high level
Number of Hoppers for display
"Gate Cycle Time" values assume stroke limiters installed
in hoppers #2 & #4 & #5 thru #8
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
VIRGIN
ADDITIVE
REGRIND
ADDITIVE
ADDITIVE
ADDITIVE
ADDITIVE
ADDITIVE
LOADCELL CALEX MODULE DIPSWITCH SETTINGS
Switches set to "ON" position
#1 & #2
SPECIAL NOTES
2 - Component Blenders with R.A.M. - Consult Engineering
BF1-615.3
Chapter 7: 6BAppendix
93 of 101
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 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.
Below are the items that can be accessed for the blender:
Note: ITEMS MARKED (R) ARE READ ONLY AND ITEMS MARKED
(RW) ARE READ/WRITE
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)
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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
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Chapter 7: 6BAppendix
95 of 101
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)
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96 of 101
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)
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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)
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)
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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
HOPPER 1
HOPPER 2
HOPPER 3
HOPPER 4
HOPPER 5
HOPPER 6
1=
Out of Material
Out of Material
Out of Material
Out of Material
Out of Material
Out of Material
1
2
3
4
5
6
2=
3=
4=
5=
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
CALIBRATION ERROR. Clean out weigh hopper and check calibration
10=
12=
13=
14=
15=
16=
17=
HOPPER 1
HOPPER 2
HOPPER 3
HOPPER 4
HOPPER 5
HOPPER 6
Low Level
Low Level
Low Level
Low Level
Low Level
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.
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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.
Note: If you chose to write the recipe to the raw recipe locations you run the
risk of inadvertently entering the incorrect recipe. This is not
recommended because it will bypass all the checks that the blender
makes before letting you hit “accept new recipe”. Also if you chose to
use the raw method then you must add up the totals for your recipe and
write that at the exact same time that you write the other raw recipe
values. You must also right the batch size and recipe entry information
or the blender might not make a batch.
RECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH
The targets that are read are in lbs 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 you are not getting the “print now” bit, then refer to the blender manual
to configure “print batch data”.
Note: WHEN THE BLENDER IS NOT RUNNING THE “TARGET”
VALUES GET SET TO “999999999” AND IN THE BEGINNING OF
EACH BATCH ALL ACTUAL VALUES GET SET TO “999999999”
UNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH.
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7-6 Technical Assistance
Parts Department
[
]
[810]
Call toll-free 7am–5pm CST 800 423-3183 or call 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 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.
Service Department
[
]
[810]
Call toll-free 8am–5pm CST 800 423-3183 or call 720-7300
[
]
Emergencies after 5pm CST, call 847 439-5655
We have a qualified service department ready to help. Service contracts are available for most
of our products.
www.acscustomerservice.com
Sales Department
[810]
Call
720-7300 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact
our Sales Department for the name of the sales representative nearest you.
Contract Department
[810]
Call
720-7300 Monday–Friday, 8am–5pm CST
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.
BF1-615.3
Chapter 7: 6BAppendix
101 of 101
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