Mitsubishi Electronics 882.00273.00 Initial Set-up, Mechanical Set-up, Stroke Limiters

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3-5 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). 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

BF1-615.3

Chapter 3: 2BInstallation

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Contents We are committed to a continuing program of product improvement Write Down Your Serial Numbers Here For Future ReferenceGravimetric Slide Gate Batch Blender Mitsubishi Controller Part Number Bulletin Number BF1-615.3 Effective 11/07/07If the Shipment is Not Complete Shipping InfoUnpacking and Inspection In the Event of Shipping DamageCredit Returns Warranty ReturnsCHAPTER 2 FUNCTIONAL DESCRIPTION Table of ContentsCHAPTER 1 SAFETY CHAPTER 3 INSTALLATIONCHAPTER 7 APPENDIX CHAPTER 5 MAINTENANCECHAPTER 6 TROUBLESHOOTING CHAPTER 4 OPERATIONHopper Additive Feeder Sub-Assembly Optional Safety Symbols Used in this Manual Chapter 1 Safety1-1 How to Use This Manual Description Figure 1 Safety Tags and Warning LabelsUse care when LOADING, UNLOADING, RIGGING, or MOVING this equipment 1-2 Warnings and PrecautionsCAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVESOperator Responsibility 1-3 ResponsibilityGeneral Responsibility REMEMBER Reporting a Safety Defect Maintenance Responsibility2-1 Models Covered in This Manual AccessoriesCustomer Service Chapter 2 Functional Description2500 Figure 2 Equipment SpecificationsFigure 3 Typical Blender Assembly Dimensions and SpecificationsFigure 4 Typical Mitsubishi Controller Touch Screen Display 2-3 Typical Features and ComponentsMechanical Features Controller FeaturesSupply Hoppers Figure 5 Typical Hopper AssemblySystem Component Description Slide Gates Weigh Hopper Figure 6 Typical Slide Gate AssemblyFigure 7 Typical Weigh Hopper Assembly Operator Control Panel Display Figure 8 Typical Mixer AssemblyMix Chamber Function Figure 9 Typical Mitsubishi Controller Touch Screen DisplayFigure 10 Controller Pushbuttons & Touchscreen Tags Button22 of Figure 11 Typical Operator Screens23 of Figure 12 Typical Setup Screens24 of Position Figure 13 Mixer Slide Gate Switch Positions2-4 Optional Components Pneumatic Slide Gate below MixerAdditive Feeder Hopper Figure 15 Typical R.A.M. Hopper Blender ConfigurationFigure 16 Typical Additive Feeder Configuration Regrind Auger Metering R.A.M. HopperFail Safe Operation 2-5 Safety FeaturesSafety Circuit Standards Safety Device Lock-OutsFigure 18 Twist Cap Plug Figure 17 Electrical Disconnect PlugTwist Cap Plug Connected to Each Feeder Auger Motor Figure 19 Electrical Safety Interlock Switch Located on mixer door Electric Safety Interlock SwitchFigure 20 Blender Lifting Lugs 1 on each side Chapter 3 Installation3-2 Mechanical Installation 3-1 Uncrating the EquipmentMachine Mount Mounting ConfigurationsSite Requirements GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMER Note Larger blenders need to be braced as part of the installationMezzanine Mount Figure 21 Typical Mezzanine Mounted Batch BlenderFigure 22 Typical Floor Mount Central Blender Layout Floor Mount Central BlenderFigure 23 Customer-Supplied Pneumatic Components 3-3 Electrical Connections3-4 Pneumatic Connections Figure 24 Stroke Limiters 3-5 Initial Set-upMechanical Set-up Stroke Limiters for Metering GatesFigure 26 Display Startup Screen Weigh Hopper InstallationFigure 25 Weigh Hopper Final ConnectionsController Set-up Figure 27 Display Main Recipe ScreenBlender Controller Menu Structure Blender Calibration Current Loadcell Bits Follow Instructions Figure 28 Display Calibration Menu ScreenFigure 29 Display Calibration Screen Enter in the Calibration Weight Press here to perform the calibrationSelect a Feeder to Configure Change the Alarm Silence Delay Alarm SetupFigure 30 Display Alarm Flags & Feeder Setup Screen Feeder Calibration Auger BlendersFigure 32 PanelView Configuration Screen Network SetupFigure 31 Ethernet Setup Screen Setting Date and TimeAdditional Setup Parameters 3-6 Initial Startup General Operation Quick Start ProcedureChapter 4 Operation 4-1 Start-upNote Press “Push to Start or Stop” button to start blender 4-2 Operation ProceduresExisting Recipes Figure 34 Typical Manual Control Operator Screen Operator DisplaysFigure 33 Typical Recipe Entry Operator Screen Recipe Entry Formats Figure 35 Typical Inventory Display Operator ScreenRecipe Format Menu “Quickset” Mode Most common in injection molding Page Figure 37 Example Calculations of a 4-component blend in “Parts” mode Switching ModesRecipe Setup “Percentage” Mode Most common in extrusion and blow moldingInventory Shutdown Figure 38 Typical Batch SizesBlender Batch Size lbsFigure 40 Typical Mixer and Dump Setup Operator Screen Auto Start FeatureMixer and Dump Setup Mix TimerWeigh Hopper Dump Delay Time Re-Mix TimerWeigh Hopper Dump Time Mixer Dump Time Alarm FlagsFigure 41 Typical “Out of Material” Alarm Screen Weigh Hopper Dump CycleFigure 44 Typical “Power Interruption” Alarm Screen Figure 42 Typical “Maximum Hopper Weight” Alarm ScreenMAX HOPPER WEIGHT EXCEEDED check batch size Figure 43 Typical “Calibration Error” Alarm ScreenFigure 46 Typical “E-Stop Activated” Alarm Screen Figure 45 Typical “PLC Battery Low” Alarm ScreenPLC BATTERY LOW Figure 47 Typical Manual Control Operator Screen Feeder Clean OutTree Diagram in section 3-5 of this manual Recipe BookLoad a Saved Recipe from the Book Display Recipe ContentsFigure 48 Typical Recipe Book Operator Screen Save Running Recipe to the BookColor Changes Erase Recipe or Entire BookFigure 49 Typical Inventory Shutdown Operator Screen 4-3 Shut-downSystem model # Chapter 5 Maintenance5-1 Preventative Maintenance Schedule Figure 50 Sample Preventative Maintenance ScheduleInternal Components of the Control Panel 5-2 Preventative Maintenance5-3 Corrective Maintenance ElectricalNote The alarm contact has a maximum load of 3 amps Input Signals to Programmable ControllerOutput Signals from Programmable Controller Corrective action Chapter 6 TroubleshootingProblem 6-1 IntroductionCorrective action ProblemCorrective action warranty will be voided Service Department Chapter 7 Appendix 7-1 Technical SpecificationsEquipment Specifications Figure 52 Equipment SpecificationsAnnex B Information Figure 53 Typical Final Assembly Parts List 7-2 Drawings and DiagramsFinal Assembly 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 OptionalControl Panel Layout Figure 62 Typical Mitsubishi Controller Main Parts ListFigure 63 Typical Mitsubishi Display Main Parts List Spare Parts Kits Figure 64 Blender Spare Parts ListingFigure 65 Typical Operator Setup Screen 7-4 Addendum Service Supervisor InformationPasswords Programmable SettingsMetering Test Screen Figure 66 Typical Engineering Only Setup ScreenFactory Setup Menu Advanced Weight Options ScreenFeed Calibration Options Screen Figure 68 Typical Advanced Weight Options ScreenFeed Algorithm Options Screen Figure 69 Typical Feed Algorithm Options ScreenFigure 71 Typical Mechanical Options Screen Feeder SetupFigure 72 Typical Feeder Setup Screen Mechanical Options ScreenFigure 73 Typical Units Screen Customer Setup MenuFigure 74 Typical Ethernet Setup Screen UnitsFigure 76 Typical Alarm Log Screen Figure 75 Typical Alarm Flags & Feeder Setup ScreenAlarm Log 92 of Factory Default Setup ParametersBF1-615.3 Chapter 7 6BAppendixVIRGIN 93 ofBLENDER STARTING AND STOPPING 7-5 Mitsubishi Communications ManualNote ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITE GENERAL BLENDER INFOBLENDER 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 ExplanationUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH WRITING RECIPE EXPLANATIONRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH Sales Department Service Department7-6 Technical Assistance Parts Department