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BI - Series Batch Mixer
Index
General
The Palmer BI-Series
Batch Mixers are specifically designed with the
harsh environment user in mind. The integration of
toughness and simplicity of design makes these
mixers the hardest working, longest lasting batch
mixers on the market.
With capacities from
1 to 10 cubic feet per batch, these machines can be
sized to fit nearly any batch-mixing requirement.
Mixing efficiency is developed through the use
specialized, variable pitch mixing blade assembly,
coupled with the use of a variable frequency drive (VFD),
allowing the user to custom develop the best fit of
intensity, speed, and time for their particular core
material.
Standard Models:
- BI100 1-2.5 Cubic
Foot Batch
- BI300 2.5 - 5
Cubic Foot Batch
- BI500 5 - 10 Cubic
Foot Batch
In all aspects of the
BI-Series design the operators and maintenance
personnel that will be working on the machine were
of utmost priority. The design is simple, rugged,
and easy to maintain. This is the premise on which
Palmer Mfg. has grown and is certainly the basis for
the BI-Series.
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Drive
 The
mixing blade assembly is powered by a 10 to 25 HP
drive based on the size of the unit. The drive is
integrally coupled to a right angle gearbox that
drives the mixing blade. The included variable
frequency drive ties directly to the drive motor for
simple adjustment of high and low rotational speed
of the blade.
The primary mixing
gearbox is mounted directly under the floor of the
mixing chamber eliminating difficult to reach and
maintain seal-sets below the mixer. All chamber
sealing is accomplished inside the body of the
mixer. With no chains, belts, or extraneous seals to
maintain, the BI-Series provides greater mixing
up-time and minimal preventative maintenance time.
The mixing blade can
be removed from the primary rotation shaft (leaving
the shaft in the mixing chamber) or the entire blade
/ shaft assembly can be removed together. The keyed
drive shaft simply drops in from the top and is
retained from the bottom side of the gearbox.
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Mixing Chamber
 The
mixing chamber is built of three primary components:
a heavy wall outer body (3/4 minimum thickness)
comprises the external shell. A ½ thick abrasion
resistant inner lining coupled with a 1 thick
abrasion resistant floor significantly reduce liner
changes.
Poured urethane inner
linings are available as optional components. Either
the wall liner or floor liner or both can be
produced from urethane.
Two massive mixing
chamber doors allow easy access to both sides of the
mixer allowing easy cleaning and replacement of wear
parts. As required, the lid is removable for rebuild
or replacement of interior liners.
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Discharge
Door
 Door
seal is maintained using a heavy-duty, high load air
cylinder coupled with a heavy-duty linkage for
positive door closure. This door sealing method is
not only simple, but rugged.
The discharge chute
is constructed of 1/2 thick steel with a
ultra-high molecular weight polyethylene liner,
preventing sticking and build-up of material. The
liner is easily replaceable for maintenance as
required.
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Mixing Cycle
- The mixer is
started in low speed and the butterfly valve
opens regulating material flow into the mixing
chamber. Low speed is used during fill to
minimize airborne dust. If installed, the powder
feeder will feed in additive material during the
filling process to ensure homogeneous dry
mixing.
- The liquid
components are then injected utilizing
low-pressure air assist. The air assist is
constantly active to ensure that the jet ports
do not clog.
- Once resins are
injected, the mixer accelerates to the
high-speed mix for the necessary mixing
duration.
- After the mixing
time has expired, the mixer switches to low
speed and the discharge door opens. Low speed
discharge reduces slinging of mixed material
onto components outside the mixer body. Once the
majority of the mixed material is discharged,
the mixer shifts to high speed for final
emptying and the door closes.
- A small batch of
scrubbing material is introduced to the mixing
chamber for cleaning at high speed. This
material will be used as part of the next batch.
- Once the cleaning
cycle is complete, the mixer shuts down until
called for the next batch.
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Controls
 All
main electrical components are housed in a NEMA 12
dust tight disconnect enclosure. All components are
thoughtfully arranged for ease of operation and
maintenance.
The primary logic
component is an Allen Bradley Micrologic 1000 PLC
processor. The standard model offers four batch
recipes, which include batch size and resin levels
for all liquid and / or powder components. Batch
timing is considered to be a system function and is
programmable only through main system setup (not
individual recipes).
As an option, Palmer
Mfg. can upgrade the standard Allen Bradley
Micrologic 1000 processor to a AB SLC5XX series PLC
with full system integration. Contact our offices
for your specific requirements.
A small remote
enclosure is included to be located near the
operator station and contains the control switches
needed for automatic or hand mixer operation. In
auto mode, the mixer will run when called by a bin
indicator. In hand mode, the mixer will run based on
a manual call signal from the operator. The wiring
of this control enclosure is the responsibility of
the customer.
The control system
has a master safety relay with mixing door limit
switch and emergency stop pushbuttons on both the
machine cabinet and the operator station.
There are two modes
of mixer operation:
- HAND A manual
mode of operation in which any or all aspects of
the mixer are operated via two-position
switches, located on the door of the enclosure.
- AUTO All
aspects of the mixer are run from a remote panel
located at the operators station or
interlocked to a core machine level indicator.
A single, three-phase
electrical service is required. An internal KVA
transformer housed in the enclosure provides the
120-volt control power.
The pump circuitry
consists of soft or programmable and scalable
potentiometers or pump motor speed controllers
located in the PLC program used in conjunction with
state-of-the-art Pulse-Width Modulated DC Motor
Controls. The PWM regulates motor speeds to within
.5% of setpoint. The pump speed adjustment located
in the DTAM operator interface mounted on the door
of the main electrical enclosure allows for simple,
positive pump adjustments.
- Main Enclosure
Hoffman NEMA 12 Disconnect
- Main Control
Components Allen Bradley
- Control
Transformer Acme
- Main Voltage
Requirements 60-AMP, 480-Volt, 3-Phase,
60-HZ
- Control Voltage
120-Volt
- Pump Drive Voltage
0 to 90-Volt DC
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Pumping System
 The
pumping system is housed in a separate NEMA
enclosure to protect he components from the plant
environment. The system will consist of:
- TWO Cast iron
gear pumps of wetted packing design
- TWO Ό-HP DC
volt gearhead motors
- TWO Fast
action stainless steel air actuated ball valves
The DC volt gearhead
motors provide consistent output RPM across their
full output range.
The pumps are direct
coupled to the drive motors to eliminate the
inaccuracy found in chain, belt, and gear reduction
couplings. The direct in-line coupling also
eliminates all side load on pump bearings and
packing, extending the life of the pump.
Fast response air
actuated ball valves provide instant routing of
chemicals to the mixing chamber.
A low-pressure air
jet system provides a low CFM airflow to help
introduce the chemicals into the mixing chamber and
keep the mixing chamber resin ports clear. The air
jet system is fully adjustable via flow controls
located in the electrical enclosure.
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BI-Series Options
to Consider
Fixed Volume
Material Metering System Material of a
known and consistent density can be metered into the
batch mixing system by a fixed, known volume. An
upper material flow valve opens to allow material
into a fixed volume chamber. When the mixer calls
for material, the upper butterfly closes and the
lower butterfly opens. This low cost material
metering system is the ultimate in simplicity.
Material volume is adjusted using a variable height
material feed pipe. Accuracy is 2% or better based
on weight
Integrated
Triple Load Cell Weighing System The
standard operation of the mixer uses timed fill
rate. An optional, PLC controlled three-load cell
system can be installed for material addition with
accuracy of 0.5% or better.
Flo-Watch
Liquid Monitoring System - This system
provides positive displacement flow meters for Parts
1 and 2. Based on the calibrated material weight,
the liquid pumps are run until the preset binder
level requirements have been met. The accuracy of
these flow meters completely offsets the need for
high maintenance, cumbersome, fixed volume chemical
addition cylinders. This option includes the
standard resin recirculation option
Powder Feeder
- This flexible hopper volumetric feeder is used to
add powder materials to the mixing chamber
SCS Material
Delivery System This option allows the
mixer to remain stationary while a car delivers
mixed material to one of multiple core machines.
This option also allows a batch of material to be
mixed while the shuttle car is delivering, reducing
core machine waiting time. These systems are
standard from Palmer Manufacturing. Advise our sales
department of your exact needs for a precise quote.
Dual Discharge
Doors Dual discharge doors are available
as a standard option. The second door can lead to a
clean-out chute or, depending on the installation,
can feed a second core machine. Doors are located
180° apart.
 Recirculating
Pumps Traditionally known for providing
resins of homogeneous temperature in difficult
environments, this standard option provides for high
speed, air-actuated three way ball valves for the
standard two pump system. Recirculation of acid
cured systems is also available.
Urethane Liner
Poured bottom and side liners area available.
Either or both liners can be replaced with urethane.
Liners are easily replaced and are held in place
with cast-in studs nutted on the outside of the
mixing chamber.
 PLC
Integration All Palmer BI-Series mixers
come standard with PLC mixer control packages.
Consult with our sales department for your exact PLC
integration needs if your requirements are greater
than those listed. Please note that our standard PLC
upgrade package is Allen Bradley SLC 502 Series.
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