Mitsubishi Electric 882.00273.00 - Manuals

Hopper Additive Feeder Sub-Assembly (Optional).............................................. 79 Weigh Hopper Sub-assembly .............................................................................. 80 Slide Gate Sub-assembly ...........................................................................

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 mainte...

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

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 internatio...

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 accesso...

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 Mi...

Figure 2: Equipment Specifications 150 500 900 2500 4000 6000 150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725) 2 to 4 2 to 6 2.0 (50) 2.5 (63) 1.5 (38) 2.0 (50) 0.7 (20) 5.2 (145) 0.2 (5) 3.6 (100) 0.07 (2) 0.18 (5) 0.38 (11) 0.82 (23) 1.23 (34) 2.17 (61) 1.5 (0.7) 4 (1.8) 8 (3.6) 25...

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 St...

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

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 va...

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...

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

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

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

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 ...

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 Confi...

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 ...

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 coun...

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! ...

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 ho...

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...

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...

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 nu...

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 ...

Blender Controller Menu Structure 101 “Recipe Book” Page ¾ Save the running recipe to the book ¾ Delete a stored recipe ¾ Load a stored recipe ¾ Erase all stored recipes ¾ Modify the product ID for a stored recipe ¾ Return to the “Recipe” page “Clean Out” Page ¾ Empty the blender hopper(s) ¾ Manuall...

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...

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. ...

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 Sile...

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 ...

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 th...

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 informat...

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 ...

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 a...

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 ...

“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 config...

“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 ...

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, me...

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 ...

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 ...

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 Op...

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...

Figure 48: Typical Recipe Book Operator Screen Erase One Stored Recipe Select a Stored Recipe Stored Recipe Details Erase EntireBook 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 r...

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 boo...

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 empty...

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 shou...

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 lubricat...

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 lev...

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 ou...

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 To...

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 S...

Problem Corrective action I can’t calibrate the Scale without an error message. This Is caused by the difference in bits not being large enough. Using the Direct Scale Readout, examine current loadcell bits with and without the calibration weight. If the bits do not change significantly, then check ...

Chapter 7: Appendix 7-1 Technical Specifications Equipment Specifications Figure 52: Equipment Specifications 150 500 900 2500 4000 6000 150 (68) 500 (227) 900 (410) 2500 (1135) 4000 (1815) 6000 (2725) 2 to 4 2 to 6 2.0 (50) 2.5 (63) 1.5 (38) 2.0 (50) 0.7 (20) 5.2 (145) 0.2 (5) 3.6 (100) 0.07 (2) 0....

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

7-2 Drawings and Diagrams Final Assembly Figure 53: Typical Final Assembly Parts List # Description 150 900 2500 4000 6000 1 Mixer Assembly A0771677 A0771682 A0771683 A0771663 A0771691 A0771692 3-Component Hopper Assembly N/A A0771687 A0771664 A0771700 2-Component Hopper Assembly N/A A0771686 A07716...

Figure 54: Typical Mixer Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 FRAME 872.00093.00 872.00094.00 A0770301 872.00224.00 2 FRAME EXTENSION (NOT SHOWN) N/A 872.00225.00 3 TOP PLATE 872.00095.00 872.00096.00 A0770300 872.00226.00 4 MOUNTING BRACKET – MIXER MOTOR 872.00097.00 872.00098...

Hopper Sub-assembly Figure 55: Typical Hopper Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 3-COMPONENT HOPPER 872.00118.00 A0569131 872.00240.00 1 2-COMPONENT HOPPER 872.00119.00 A0770299 872.00241.00 3 LEXAN DOOR A0770286 4 DOOR LATCH A0770076 5 3.5” SIGHT GLASS A0569154 N/A 6 4.5” SIGH...

Hopper Additive Feeder Sub-Assembly (Optional) Figure 57: Typical Additive Feeder Hopper Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 THROAT A0541201 2 MOTOR MOUNT BRACKET A0541229 3 MOTOR – AUGER 51450G 4 THROAT ADAPTER – 2” RISER 872.00537.00 N/A HOPPER 1.0 CU.FT. A0541207 N/A 5 HOPP...

Weigh Hopper Sub-assembly Figure 58: Typical Weigh Hopper Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 WEIGH HOPPER 872.00103.00 872.00104.00 A0770312 872.00229.00 872.00230.00 2 AIR CYLINDER 245.00003.00 A0770248 3 CLEVIS – AIR CYLINDER 35460 35449 4 FITTING – AIR TUBING 35086K 35085K...

Slide Gate Sub-assembly Figure 59: Typical Slidegate Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 HOUSING (DOUBLE DIAMOND) (#1-4) 872.00114.00 A0770304 872.00524.00 HOUSING (SQUARE / DIAMOND) (#1-4) A0770308 N/A 1 HOUSING (DOUBLE DIAMOND) (#5-6) 872.00113.00 A0770308 872.00235.00 GATE – ...

Knife Gate Sub-assembly HD (Optional) Figure 60: Typical Knife Gate (below mixer) Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 BASE FRAME 07990 2 MOLDED THROAT 53413 3 SPACER PLATE 08286 4 FLANGE ADAPTER 08292 5 KNIFE BLADE 10644 6 MOUNTING BRACKET – AIR CYLINDER 33088 7 AIR CYLINDER 3...

Knife Gate Sub-assembly RD (Optional) Figure 61: Typical Knife Gate (floor stand) Assembly Parts List # DESCRIPTION 500 900 2500 4000 6000 1 HOUSING FRAME 872.00297.00 2 GUARD SAFETY COVER 872.00236.00 3 ROD GUIDE 832.00049.00 4 GATE – SLIDE BLADE 872.00236.00 5 AIR CYLINDER 245.00016.00 6 CLEVIS – ...

Control Panel Layout Figure 62: Typical Mitsubishi Controller Main Parts List # Description 150 500 900 2500 4000 6000 1 Mitsubishi PLC FX2N-32MR A0569702 2 Mitsubishi PLC EEPROM A0569703 3 24 vdc Power Supply A0563932 4 Calex Module – Load Cell Amplifier 724.00117.00 5 Alarm Light Yellow Strobe 24 ...

7-3 Spare Parts Kits Figure 64: Blender Spare Parts Listing M o d e l 150 5 00 900 2500 400 0 60 00 K IT "A" (C o n su m ab le s) A05 74120 A0 57413 4 A05741 37 A057 4125 A05 74140 A0 57414 3 Loa d C ell As s em bly (w ith out plug) # 724.00 767.0 0 724.0 0768 .00 724 .00770 .00 72 4.007 71....

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 incl...

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 m...

This setting should not be modified except by the developer except under unusual circumstances. Figure 68: Typical Advanced Weight Options Screen 101 Feed Algorithm Options Screen This screen allows the user to configure how the blender metering algorithm works. The user can adjust the Initial perce...

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 Network Set...

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 r...

Factory Default Setup Parameters Model Number 150 500 900 2500 4000 6000 Recipe Entry Mode PERCENTAGE Metering OrderBatch Size (lbs) 2.0 4.0 8.0 25.0 35.0 45.0 Inventory ShutdownBatch Ready ModeAutoStart ModeWeighing mode Blender NumberAuto Print InventoryAuto Clear InventoryAuto Print/Clear Interva...

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 a...

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 (...

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,...

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 reci...

7-6 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [810] 720-7300; Fax [810] 720-2598 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment...