Mitsubishi Electronics 882.00273.00 Functional Description, Models Covered in This Manual

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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.

BF1-615.3

Chapter 2: 1BFunctional Description

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Contents Gravimetric Slide Gate Batch Blender Mitsubishi Controller Write Down Your Serial Numbers Here For Future ReferencePart Number Bulletin Number BF1-615.3 Effective 11/07/07 We are committed to a continuing program of product improvementUnpacking and Inspection Shipping InfoIn the Event of Shipping Damage If the Shipment is Not CompleteCredit Returns Warranty ReturnsCHAPTER 1 SAFETY Table of ContentsCHAPTER 3 INSTALLATION CHAPTER 2 FUNCTIONAL DESCRIPTIONCHAPTER 6 TROUBLESHOOTING CHAPTER 5 MAINTENANCECHAPTER 4 OPERATION CHAPTER 7 APPENDIXHopper Additive Feeder Sub-Assembly Optional 1-1 How to Use This Manual Chapter 1 SafetySafety Symbols Used in this Manual Description Figure 1 Safety Tags and Warning LabelsCAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON 1-2 Warnings and PrecautionsWear SAFETY GLASSES and WORK GLOVES Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipmentGeneral Responsibility 1-3 ResponsibilityOperator Responsibility REMEMBER Reporting a Safety Defect Maintenance ResponsibilityCustomer Service AccessoriesChapter 2 Functional Description 2-1 Models Covered in This ManualFigure 3 Typical Blender Assembly Figure 2 Equipment SpecificationsDimensions and Specifications 2500Mechanical Features 2-3 Typical Features and ComponentsController Features Figure 4 Typical Mitsubishi Controller Touch Screen DisplaySystem Component Description Figure 5 Typical Hopper AssemblySupply Hoppers Slide Gates Weigh Hopper Figure 6 Typical Slide Gate AssemblyFigure 7 Typical Weigh Hopper Assembly Mix Chamber Figure 8 Typical Mixer AssemblyOperator Control Panel Display Figure 10 Controller Pushbuttons & Touchscreen Tags Figure 9 Typical Mitsubishi Controller Touch Screen DisplayButton Function22 of Figure 11 Typical Operator Screens23 of Figure 12 Typical Setup Screens24 of 2-4 Optional Components Figure 13 Mixer Slide Gate Switch PositionsPneumatic Slide Gate below Mixer PositionFigure 16 Typical Additive Feeder Configuration Figure 15 Typical R.A.M. Hopper Blender ConfigurationRegrind Auger Metering R.A.M. Hopper Additive Feeder HopperSafety Circuit Standards 2-5 Safety FeaturesSafety Device Lock-Outs Fail Safe OperationTwist Cap Plug Connected to Each Feeder Auger Motor Figure 17 Electrical Disconnect PlugFigure 18 Twist Cap Plug Figure 19 Electrical Safety Interlock Switch Located on mixer door Electric Safety Interlock Switch3-2 Mechanical Installation Chapter 3 Installation3-1 Uncrating the Equipment Figure 20 Blender Lifting Lugs 1 on each sideSite Requirements Mounting ConfigurationsMachine Mount Mezzanine Mount Note Larger blenders need to be braced as part of the installationFigure 21 Typical Mezzanine Mounted Batch Blender GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMERFigure 22 Typical Floor Mount Central Blender Layout Floor Mount Central Blender3-4 Pneumatic Connections 3-3 Electrical ConnectionsFigure 23 Customer-Supplied Pneumatic Components Mechanical Set-up 3-5 Initial Set-upStroke Limiters for Metering Gates Figure 24 Stroke LimitersFigure 25 Weigh Hopper Weigh Hopper InstallationFinal Connections Figure 26 Display Startup ScreenController Set-up Figure 27 Display Main Recipe ScreenBlender Controller Menu Structure Blender Calibration Figure 29 Display Calibration Screen Figure 28 Display Calibration Menu ScreenEnter in the Calibration Weight Press here to perform the calibration Current Loadcell Bits Follow InstructionsFigure 30 Display Alarm Flags & Feeder Setup Screen Alarm SetupFeeder Calibration Auger Blenders Select a Feeder to Configure Change the Alarm Silence DelayFigure 31 Ethernet Setup Screen Network SetupSetting Date and Time Figure 32 PanelView Configuration ScreenAdditional Setup Parameters 3-6 Initial Startup Chapter 4 Operation Quick Start Procedure4-1 Start-up General OperationExisting Recipes 4-2 Operation ProceduresNote Press “Push to Start or Stop” button to start blender Figure 33 Typical Recipe Entry Operator Screen Operator DisplaysFigure 34 Typical Manual Control Operator Screen Recipe Entry Formats Figure 35 Typical Inventory Display Operator ScreenRecipe Format Menu “Quickset” Mode Most common in injection molding Page Recipe Setup Switching Modes“Percentage” Mode Most common in extrusion and blow molding Figure 37 Example Calculations of a 4-component blend in “Parts” modeBlender Figure 38 Typical Batch SizesBatch Size lbs Inventory ShutdownMixer and Dump Setup Auto Start FeatureMix Timer Figure 40 Typical Mixer and Dump Setup Operator ScreenWeigh Hopper Dump Time Re-Mix TimerWeigh Hopper Dump Delay Time Figure 41 Typical “Out of Material” Alarm Screen Alarm FlagsWeigh Hopper Dump Cycle Mixer Dump TimeMAX HOPPER WEIGHT EXCEEDED check batch size Figure 42 Typical “Maximum Hopper Weight” Alarm ScreenFigure 43 Typical “Calibration Error” Alarm Screen Figure 44 Typical “Power Interruption” Alarm ScreenPLC BATTERY LOW Figure 45 Typical “PLC Battery Low” Alarm ScreenFigure 46 Typical “E-Stop Activated” Alarm Screen Figure 47 Typical Manual Control Operator Screen Feeder Clean OutTree Diagram in section 3-5 of this manual Recipe BookFigure 48 Typical Recipe Book Operator Screen Display Recipe ContentsSave Running Recipe to the Book Load a Saved Recipe from the BookColor Changes Erase Recipe or Entire BookFigure 49 Typical Inventory Shutdown Operator Screen 4-3 Shut-down5-1 Preventative Maintenance Schedule Chapter 5 MaintenanceFigure 50 Sample Preventative Maintenance Schedule System model #5-3 Corrective Maintenance 5-2 Preventative MaintenanceElectrical Internal Components of the Control PanelOutput Signals from Programmable Controller Input Signals to Programmable ControllerNote The alarm contact has a maximum load of 3 amps Problem Chapter 6 Troubleshooting6-1 Introduction Corrective actionCorrective action ProblemCorrective action warranty will be voided Service Department Equipment Specifications 7-1 Technical SpecificationsFigure 52 Equipment Specifications Chapter 7 AppendixAnnex B Information Final Assembly 7-2 Drawings and DiagramsFigure 53 Typical Final Assembly Parts List 75 of Mixer Sub-AssemblyA0770319 Figure 54 Typical Mixer Assembly Parts ListFigure 55 Typical Hopper Assembly Parts List Hopper Sub-assemblyFigure 56 Typical R.A.M. Hopper Assembly Parts List Hopper R.A.M. Regrind Auger Metering Sub-Assembly OptionalFigure 57 Typical Additive Feeder Hopper Assembly Parts List Hopper Additive Feeder Sub-Assembly OptionalFigure 58 Typical Weigh Hopper Assembly Parts List Weigh Hopper Sub-assemblyFigure 59 Typical Slidegate Assembly Parts List Slide Gate Sub-assemblyFigure 60 Typical Knife Gate below mixer Assembly Parts List Knife Gate Sub-assembly HD OptionalFigure 61 Typical Knife Gate floor stand Assembly Parts List Knife Gate Sub-assembly RD OptionalFigure 63 Typical Mitsubishi Display Main Parts List Figure 62 Typical Mitsubishi Controller Main Parts ListControl Panel Layout Spare Parts Kits Figure 64 Blender Spare Parts ListingPasswords 7-4 Addendum Service Supervisor InformationProgrammable Settings Figure 65 Typical Operator Setup ScreenFactory Setup Menu Figure 66 Typical Engineering Only Setup ScreenAdvanced Weight Options Screen Metering Test ScreenFeed Algorithm Options Screen Figure 68 Typical Advanced Weight Options ScreenFigure 69 Typical Feed Algorithm Options Screen Feed Calibration Options ScreenFigure 72 Typical Feeder Setup Screen Feeder SetupMechanical Options Screen Figure 71 Typical Mechanical Options ScreenFigure 74 Typical Ethernet Setup Screen Customer Setup MenuUnits Figure 73 Typical Units ScreenAlarm Log Figure 75 Typical Alarm Flags & Feeder Setup ScreenFigure 76 Typical Alarm Log Screen BF1-615.3 Factory Default Setup ParametersChapter 7 6BAppendix 92 ofVIRGIN 93 ofNote ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITE 7-5 Mitsubishi Communications ManualGENERAL BLENDER INFO BLENDER STARTING AND STOPPINGBLENDER ALARMS INVENTORY INFO CURRENT RECIPE INFO THIS IS THE RECIPE THAT IS CURRENTLY BEING MADE RECIPE INFO THIS IS WHERE YOU RIGHT THE NEW RECIPE TORECIPE BOOK MANIPULATION TARGETS VS. ACTUAL WEIGHT INFOFIXED DECIMAL EXPLANATION Alarm Number ExplanationRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH WRITING RECIPE EXPLANATIONUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH 7-6 Technical Assistance Service DepartmentParts Department Sales Department