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Colortronic Colotronic Blender Manual

Gravimetric slide gate batch blender
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Gravimetric Slide Gate Batch Blender
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
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.
Mitsubishi Controller
Part Number: 882.00273.00
Bulletin Number: BF1-615.3
Effective: 11/07/07
_________________________
_________________________
_________________________

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Summary of Contents for Colortronic Colotronic Blender

  • Page 1 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: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
  • Page 2 Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY..............7 How to Use This Manual ..................... 7 Safety Symbols Used in this Manual ..............7 Warnings and Precautions ..................9 Responsibility ......................10 General Responsibility ..................10 Operator Responsibility ..................10 Maintenance Responsibility.................12 Reporting a Safety Defect ...................12 CHAPTER 2: FUNCTIONAL DESCRIPTION ......
  • Page 5 Initial Set-up ......................35 Mechanical Set-up....................35 Stroke Limiters for Metering Gates ..............35 Weigh Hopper Installation................... 36 Final Connections ....................36 Controller Set-up ....................37 Blender Controller Menu Structure ..............38 Blender Calibration....................39 Alarm Setup ......................41 Network Setup ..................... 42 Setting Date and Time ..................
  • Page 6 Spare Parts Kits ......................85 Addendum (Service Supervisor Information) ............86 Programmable Settings ..................86 Factory Setup Menu ....................87 Customer Setup Menu ..................90 Factory Default Setup Parameters ..............92 Mitsubishi Communications Manual................94 Technical Assistance....................101 Parts Department ....................101 Service Department...................101 Sales Department....................101 Contract Department ..................101...

  • Page 7: Chapter 1: Safety

    Chapter 1: Safety 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.
  • Page 8 Figure 1: Safety Tags and Warning Labels Description Description Read Operation & Pinch Point Slide Gate Installation Manual Shear Point Rotating Earth Ground Mixer High Voltage Inside Protected Earth Ground Enclosure Shear Hazard Rotating Lifting Point Auger BF1-615.3 Chapter 1: 0BSafety 8 of 101...

  • Page 9: Warnings And Precautions

    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.

  • Page 10: Responsibility

    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.
  • Page 11 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. •...

  • Page 12: Maintenance Responsibility

    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.

  • Page 13: Chapter 2: Functional Description

    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 •...
  • Page 14 Figure 2: Equipment Specifications Dimensions and Specifications 2500 4000 6000 Maximum Blending Rate, lbs/hr (kgs/hr) (3) 150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725) Number of Materials to be Blended 2 to 4 2 to 6 2 to 8 Slide Gate Size - Majors, in.

  • Page 15: Typical Features And Components

    • 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.

  • Page 16: System Component Description

    • Three (3) types of recipe entry procedures available: o Quickset mode (up to 6-component) recipe entry. Color and additives are metered as a percentage of the virgin material. o Percentage mode recipe entry. Ingredients are metered as a percentage of the overall batch.

  • Page 17: Slide Gates

    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.

  • Page 18: Weigh Hopper

    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.
  • Page 19 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.

  • Page 20: Mix Chamber

    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.
  • Page 21 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) Turns power off to the blender controller.
  • Page 22 Figure 11: Typical Operator Screens BF1-615.3 Chapter 2: 1BFunctional Description 22 of 101...
  • Page 23 Figure 12: Typical Setup Screens BF1-615.3 Chapter 2: 1BFunctional Description 23 of 101...
  • Page 24 BF1-615.3 Chapter 2: 1BFunctional Description 24 of 101...

  • Page 25: Optional Components

    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.

  • Page 26: Regrind Auger Metering (R.a.m.) Hopper

    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.

  • Page 27: Safety Features

    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.

  • Page 28: Twist Cap Plug Connected To Each Feeder Auger Motor

    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.

  • Page 29: Electric Safety Interlock Switch

    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.

  • Page 30: Chapter 3: Installation

    Chapter 3: Installation 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.

  • Page 31: Site Requirements

    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.

  • Page 32: Mezzanine Mount

    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.

  • Page 33: Floor Mount (Central Blender)

    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.

  • Page 34: Electrical Connections

    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.

  • Page 35: Initial Set-Up

    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).

  • Page 36: Weigh Hopper Installation

    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.

  • Page 37: Controller Set-Up

    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.

  • Page 38: Blender Controller Menu Structure

    Blender Controller Menu Structure “Recipe” Page” (Start) “Recipe Book” Page Recipe Format Change Recipe Values by Save the running recipe to Percentage, Parts, or Quick touching the number you the book wish to change Delete a stored recipe Batch Size Touch “Accept New Recipe”...

  • Page 39: Blender Calibration

    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.
  • Page 40 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.

  • Page 41: Alarm Setup

    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.

  • Page 42: Network Setup

    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,”...

  • Page 43: Additional Setup Parameters

    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.

  • Page 44: Initial Startup

    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”...

  • Page 45: Chapter 4: Operation

    Chapter 4: Operation 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”...

  • Page 46: Existing Recipes

    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.

  • Page 47: Operator Displays

    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: •...

  • Page 48: Recipe Entry Formats

    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.
  • Page 49 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”...

  • Page 50: Quickset" Mode (Most Common In Injection Molding)

    “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.
  • Page 51 Figure 36: Example Calculations of a 5-component blend in “Quickset” mode Virgin (NAT): Additive1 (ADD): 5.00% - of virgin component Regrind (RGD): 30.00% - of total batch Additive2 (ADD): 2.00% - of virgin component Additive3 (ADD): 1.00% - of virgin component Batch Size: 10.00 lbs.

  • Page 52: Percentage" Mode (Most Common In Extrusion And Blow Molding)

    “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%.
  • Page 53 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.

  • Page 54: Mixer And Dump Setup

    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”...
  • Page 55 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.

  • Page 56: Alarm Flags

    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.
  • Page 57 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.
  • Page 58 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.

  • Page 59: Feeder Clean Out

    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.

  • Page 60: Recipe Book

    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.
  • Page 61 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.

  • Page 62: Color Changes

    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.

  • Page 63: Shut-Down

    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.

  • Page 64: Chapter 5: Maintenance

    Chapter 5: Maintenance 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.

  • Page 65: Preventative Maintenance

    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.
  • Page 66 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).

  • Page 67: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting 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.
  • Page 68 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.
  • Page 69 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 Recorded Inventory Totals don’t for material scrap or other items in your process.
  • Page 70 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.
  • Page 71 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 I can’t calibrate the Scale and without the calibration weight. If the bits do not change without an error message.

  • Page 72: Chapter 7: Appendix

    Chapter 7: Appendix Technical Specifications Equipment Specifications Figure 52: Equipment Specifications Dimensions and Specifications 2500 4000 6000 Maximum Blending Rate, lbs/hr (kgs/hr) (3) 150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725) Number of Materials to be Blended 2 to 4 2 to 6 2 to 8...

  • Page 73: Annex B Information

    Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity 4.

  • Page 74: Drawings And Diagrams

    Drawings and Diagrams Final Assembly Figure 53: Typical Final Assembly Parts List Description 2500 4000 6000 Mixer Assembly A0771677 A0771682 A0771683 A0771663 A0771691 A0771692 3-Component Hopper Assembly A0771687 A0771664 A0771700 2-Component Hopper Assembly A0771686 A0771665 A0771699 Removable Hopper Small CTB01648 Removable Hopper Large CTB02248 Slide Gate Assembly –...

  • Page 75: Mixer Sub-Assembly

    Mixer Sub-Assembly BF1-615.3 Chapter 7: 6BAppendix 75 of 101...
  • Page 76 Figure 54: Typical Mixer Assembly Parts List DESCRIPTION 2500 4000 6000 FRAME 872.00093.00 872.00094.00 A0770301 872.00224.00 FRAME EXTENSION (NOT SHOWN) 872.00225.00 TOP PLATE 872.00095.00 872.00096.00 A0770300 872.00226.00 MOUNTING BRACKET – MIXER 872.00097.00 872.00098.00 A0770316 MOTOR MIX CHAMBER BACK PLATE 872.00099.00 872.00100.00 A0770333 872.00227.00...

  • Page 77: Hopper Sub-Assembly

    Hopper Sub-assembly Figure 55: Typical Hopper Assembly Parts List DESCRIPTION 2500 4000 6000 3-COMPONENT HOPPER 872.00118.00 A0569131 872.00240.00 2-COMPONENT HOPPER 872.00119.00 A0770299 872.00241.00 LEXAN DOOR A0770286 DOOR LATCH A0770076 3.5” SIGHT GLASS A0569154 4.5” SIGHT GLASS A0770323 (OPTIONAL) 2” DRAIN W/ MANUAL A0569162 GATE (NOT SHOWN) (OPTIONAL) 3”...

  • Page 78: Hopper R.a.m. (Regrind Auger Metering) Sub-Assembly (Optional)

    Hopper R.A.M. (Regrind Auger Metering) Sub-Assembly (Optional) Figure 56: Typical R.A.M. Hopper Assembly Parts List DESCRIPTION 2500 4000 6000 THROAT 07822-1 CLAMP A0548808 FEEDER TUBE 872.00426.00 DRAIN HOUSING 08806A-HYD DRAIN SLIDE GATE 08806B MOTOR MOUNT BRACKET 08451 SEAL – AUGER - TEFLON 55372 MOTOR - AUGER 720.00004.00...

  • Page 79: Hopper Additive Feeder Sub-Assembly (Optional)

    Hopper Additive Feeder Sub-Assembly (Optional) Figure 57: Typical Additive Feeder Hopper Assembly Parts List DESCRIPTION 2500 4000 6000 THROAT A0541201 MOTOR MOUNT BRACKET A0541229 MOTOR – AUGER 51450G THROAT ADAPTER – 2” RISER 872.00537.00 HOPPER 1.0 CU.FT. A0541207 HOPPER 2.0 CU.FT. A0541208 SIGHTGLASS –...

  • Page 80: Weigh Hopper Sub-Assembly

    Weigh Hopper Sub-assembly Figure 58: Typical Weigh Hopper Assembly Parts List DESCRIPTION 2500 4000 6000 WEIGH HOPPER 872.00103.00 872.00104.00 A0770312 872.00229.00 872.00230.00 AIR CYLINDER 245.00003.00 A0770248 CLEVIS – AIR 35460 35449 CYLINDER FITTING – AIR 35086K 35085K TUBING AIR TUBING 35300K (NOT SHOWN) BF1-615.3...

  • Page 81: Slide Gate Sub-Assembly

    Slide Gate Sub-assembly Figure 59: Typical Slidegate Assembly Parts List DESCRIPTION 2500 4000 6000 HOUSING (DOUBLE DIAMOND) (#1-4) 872.00114.00 A0770304 872.00524.00 HOUSING (SQUARE / DIAMOND) (#1-4) A0770308 872.00235.00 HOUSING (DOUBLE DIAMOND) (#5-6) 872.00113.00 A0770308 GATE – DIAMOND (#1-4) A0770309 A0770305 872.00237.00 GATE –...

  • Page 82: Knife Gate Sub-Assembly Hd (Optional)

    Knife Gate Sub-assembly HD (Optional) Figure 60: Typical Knife Gate (below mixer) Assembly Parts List DESCRIPTION 2500 4000 6000 BASE FRAME 07990 MOLDED THROAT 53413 SPACER PLATE 08286 FLANGE ADAPTER 08292 KNIFE BLADE 10644 MOUNTING BRACKET – AIR CYLINDER 33088 AIR CYLINDER 33091 MOUNTING NUT –...

  • Page 83: Knife Gate Sub-Assembly Rd (Optional)

    Knife Gate Sub-assembly RD (Optional) Figure 61: Typical Knife Gate (floor stand) Assembly Parts List DESCRIPTION 2500 4000 6000 HOUSING FRAME 872.00297.00 GUARD SAFETY COVER 872.00236.00 ROD GUIDE 832.00049.00 GATE – SLIDE BLADE 872.00236.00 AIR CYLINDER 245.00016.00 CLEVIS – AIR CYLINDER A0770296 NUT –...

  • Page 84: Control Panel Layout

    Control Panel Layout Figure 62: Typical Mitsubishi Controller Main Parts List Description 2500 4000 6000 Mitsubishi PLC FX2N-32MR A0569702 Mitsubishi PLC EEPROM A0569703 24 vdc Power Supply A0563932 Calex Module – Load Cell Amplifier 724.00117.00 Alarm Light Yellow Strobe 24 vdc...

  • Page 85: Spare Parts Kits

    Spare Parts Kits Figure 64: Blender Spare Parts Listing Model 2500 4000 6000 KIT "A" (Consumables) A0574120 A0574134 A0574137 A0574125 A0574140 A0574143 Load Cell Assembly (without plug) 724.00767.00 724.00768.00 724.00770.00 724.00771.00 724.00772.00 Mixer High Level Sensor A0556548 (5) Fuses, 1.5 Amp (5) A0542200 (5) Fuses, 3.0 Amp (5) A0542207...

  • Page 86: Addendum (Service Supervisor Information)

    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.

  • Page 87: Factory Setup Menu

    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.
  • Page 88 This setting should not be modified except by the developer except under unusual circumstances. Figure 68: Typical Advanced Weight Options Screen Adjust the limit Weight Filter for “Hopper Over 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.
  • Page 89 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.

  • Page 90: Customer Setup Menu

    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 Change Target vs.
  • Page 91 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.

  • Page 92: Factory Default Setup Parameters

    Factory Default Setup Parameters Model Number 2500 4000 6000 ALL WEIGHT VALUES RECORDED IN POUNDS (DIVIDE BY 2.20462 FOR KILOGRAMS) RECIPE FORMAT Recipe Entry Mode PERCENTAGE "EZ" MODE / "QUICK SET" MODE Metering Order 12345678 Batch Size (lbs) 25.0 35.0 45.0 Inventory Shutdown Batch Ready Mode...
  • Page 93 Model Number 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...

  • Page 94: Mitsubishi Communications Manual

    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.
  • Page 95 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)
  • Page 96 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)
  • Page 97 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)
  • Page 98 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...
  • Page 99 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...
  • Page 100 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.

  • Page 101: Technical Assistance

    Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [810] 720-7300; Fax [810] 720-2598 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency.

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