Mitsubishi Electronics 882.00273.00 “Percentage” Mode Most common in extrusion and blow molding

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“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%. If they don’t, an error message appears on the Recipe screen and prevents the recipe from being accepted. All hoppers are a percentage of the total batch size.

Note: All ingredients are weighed as a percentage of the total batch. “Parts” Mode (Often used in Compounding Applications)

The “Parts” recipe entry mode lets the operator enter in values based on a parts ratio rather than a percentage. Each entry can be up to 999.99 and the total of all hoppers does not have to be 100. After all values are entered, the total parts are calculated. The individual hopper target is then calculated based on each hopper’s entered parts. These parts represent ratios of the total batch. For instance: Hop 1=300 parts, Hop 2=100 parts, Hop 3=10 parts, Hop 4=5 parts. This would mean that if the batch was divided into 415 parts, then Hop 1 would make up 300 of those parts, Hop 2 would make up 100, Hop 3 10 parts, and Hop 4 5 parts.

Note: The preset part will be divided by the total of all parts, with each part representing the calculated weight for ratio control.

Figure 37: Example Calculations of a 4-component blend in “Parts” mode

Feeder Tag

 

Preset Part

Calculated Weight

 

(Ratio Control)

 

 

 

Virgin

#1

7,200

7,200/10,000

Regrind

#2

2,000

2,000/10,000

Color

#3

500

500/10,000

Additive

#4

300

300/10,000

Total:

 

10,000

 

Current Recipe Menu

Throughout the menu structure, the top left corner of the display will list the name of the current screen that you are in. Each individual button will indicate instructions for keystrokes. In the Recipe Format menu shown on the previous page, pressing on the mode button displayed at the top of the screen will show the Current Recipe menu.

Note: The blender will always run the percentages shown in the Current Recipe menu display.

Switching Modes

Recipe Modes can be switched while the blender is making a batch. At any time the operator can switch the recipe entry mode without affecting the current batch being made. The recipe mode is part of the “New Recipe” and is separate from the running recipe.

Recipe Setup

Batch Size

The Slide Gate/Auger blending system is a gravimetric batching system. The blender will weigh a preprogrammed batch of material each cycle. This batch size is determined by the blender’s weigh hopper size, the current recipe, and the bulk density of the ingredients.

BF1-615.3

Chapter 4: 3BOperation

52 of 101

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Contents Write Down Your Serial Numbers Here For Future Reference Gravimetric Slide Gate Batch Blender Mitsubishi ControllerPart Number Bulletin Number BF1-615.3 Effective 11/07/07 We are committed to a continuing program of product improvementShipping Info Unpacking and InspectionIn the Event of Shipping Damage If the Shipment is Not CompleteWarranty Returns Credit ReturnsTable of Contents CHAPTER 1 SAFETYCHAPTER 3 INSTALLATION CHAPTER 2 FUNCTIONAL DESCRIPTIONCHAPTER 5 MAINTENANCE CHAPTER 6 TROUBLESHOOTINGCHAPTER 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 Figure 1 Safety Tags and Warning Labels Description1-2 Warnings and Precautions CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ONWear SAFETY GLASSES and WORK GLOVES Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipmentGeneral Responsibility 1-3 ResponsibilityOperator Responsibility REMEMBER Maintenance Responsibility Reporting a Safety DefectAccessories Customer ServiceChapter 2 Functional Description 2-1 Models Covered in This ManualFigure 2 Equipment Specifications Figure 3 Typical Blender AssemblyDimensions and Specifications 25002-3 Typical Features and Components Mechanical FeaturesController Features Figure 4 Typical Mitsubishi Controller Touch Screen DisplaySystem Component Description Figure 5 Typical Hopper AssemblySupply Hoppers Slide Gates Figure 6 Typical Slide Gate Assembly Weigh HopperFigure 7 Typical Weigh Hopper Assembly Mix Chamber Figure 8 Typical Mixer AssemblyOperator Control Panel Display Figure 9 Typical Mitsubishi Controller Touch Screen Display Figure 10 Controller Pushbuttons & Touchscreen TagsButton FunctionFigure 11 Typical Operator Screens 22 ofFigure 12 Typical Setup Screens 23 of24 of Figure 13 Mixer Slide Gate Switch Positions 2-4 Optional ComponentsPneumatic Slide Gate below Mixer PositionFigure 15 Typical R.A.M. Hopper Blender Configuration Figure 16 Typical Additive Feeder ConfigurationRegrind Auger Metering R.A.M. Hopper Additive Feeder Hopper2-5 Safety Features Safety Circuit StandardsSafety Device Lock-Outs Fail Safe OperationTwist Cap Plug Connected to Each Feeder Auger Motor Figure 17 Electrical Disconnect PlugFigure 18 Twist Cap Plug Electric Safety Interlock Switch Figure 19 Electrical Safety Interlock Switch Located on mixer doorChapter 3 Installation 3-2 Mechanical Installation3-1 Uncrating the Equipment Figure 20 Blender Lifting Lugs 1 on each sideSite Requirements Mounting ConfigurationsMachine Mount Note Larger blenders need to be braced as part of the installation Mezzanine MountFigure 21 Typical Mezzanine Mounted Batch Blender GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMERFloor Mount Central Blender Figure 22 Typical Floor Mount Central Blender Layout3-4 Pneumatic Connections 3-3 Electrical ConnectionsFigure 23 Customer-Supplied Pneumatic Components 3-5 Initial Set-up Mechanical Set-upStroke Limiters for Metering Gates Figure 24 Stroke LimitersWeigh Hopper Installation Figure 25 Weigh HopperFinal Connections Figure 26 Display Startup ScreenFigure 27 Display Main Recipe Screen Controller Set-upBlender Controller Menu Structure Blender Calibration Figure 28 Display Calibration Menu Screen Figure 29 Display Calibration ScreenEnter in the Calibration Weight Press here to perform the calibration Current Loadcell Bits Follow InstructionsAlarm Setup Figure 30 Display Alarm Flags & Feeder Setup ScreenFeeder Calibration Auger Blenders Select a Feeder to Configure Change the Alarm Silence DelayNetwork Setup Figure 31 Ethernet Setup ScreenSetting Date and Time Figure 32 PanelView Configuration ScreenAdditional Setup Parameters 3-6 Initial Startup Quick Start Procedure Chapter 4 Operation4-1 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 Figure 35 Typical Inventory Display Operator Screen Recipe Entry FormatsRecipe Format Menu “Quickset” Mode Most common in injection molding Page Switching Modes Recipe Setup“Percentage” Mode Most common in extrusion and blow molding Figure 37 Example Calculations of a 4-component blend in “Parts” modeFigure 38 Typical Batch Sizes BlenderBatch Size lbs Inventory ShutdownAuto Start Feature Mixer and Dump SetupMix Timer Figure 40 Typical Mixer and Dump Setup Operator ScreenWeigh Hopper Dump Time Re-Mix TimerWeigh Hopper Dump Delay Time Alarm Flags Figure 41 Typical “Out of Material” Alarm ScreenWeigh Hopper Dump Cycle Mixer Dump TimeFigure 42 Typical “Maximum Hopper Weight” Alarm Screen MAX HOPPER WEIGHT EXCEEDED check batch sizeFigure 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 Feeder Clean Out Figure 47 Typical Manual Control Operator ScreenRecipe Book Tree Diagram in section 3-5 of this manualDisplay Recipe Contents Figure 48 Typical Recipe Book Operator ScreenSave Running Recipe to the Book Load a Saved Recipe from the BookErase Recipe or Entire Book Color Changes4-3 Shut-down Figure 49 Typical Inventory Shutdown Operator ScreenChapter 5 Maintenance 5-1 Preventative Maintenance ScheduleFigure 50 Sample Preventative Maintenance Schedule System model #5-2 Preventative Maintenance 5-3 Corrective 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 Chapter 6 Troubleshooting Problem6-1 Introduction Corrective actionProblem Corrective actionProblem warranty will be voided Service Department 7-1 Technical Specifications Equipment SpecificationsFigure 52 Equipment Specifications Chapter 7 AppendixAnnex B Information Final Assembly 7-2 Drawings and DiagramsFigure 53 Typical Final Assembly Parts List Mixer Sub-Assembly 75 ofFigure 54 Typical Mixer Assembly Parts List A0770319Hopper Sub-assembly Figure 55 Typical Hopper Assembly Parts ListHopper R.A.M. Regrind Auger Metering Sub-Assembly Optional Figure 56 Typical R.A.M. Hopper Assembly Parts ListHopper Additive Feeder Sub-Assembly Optional Figure 57 Typical Additive Feeder Hopper Assembly Parts ListWeigh Hopper Sub-assembly Figure 58 Typical Weigh Hopper Assembly Parts ListSlide Gate Sub-assembly Figure 59 Typical Slidegate Assembly Parts ListKnife Gate Sub-assembly HD Optional Figure 60 Typical Knife Gate below mixer Assembly Parts ListKnife Gate Sub-assembly RD Optional Figure 61 Typical Knife Gate floor stand Assembly Parts ListFigure 63 Typical Mitsubishi Display Main Parts List Figure 62 Typical Mitsubishi Controller Main Parts ListControl Panel Layout Figure 64 Blender Spare Parts Listing Spare Parts Kits7-4 Addendum Service Supervisor Information PasswordsProgrammable Settings Figure 65 Typical Operator Setup ScreenFigure 66 Typical Engineering Only Setup Screen Factory Setup MenuAdvanced Weight Options Screen Metering Test ScreenFigure 68 Typical Advanced Weight Options Screen Feed Algorithm Options ScreenFigure 69 Typical Feed Algorithm Options Screen Feed Calibration Options ScreenFeeder Setup Figure 72 Typical Feeder Setup ScreenMechanical Options Screen Figure 71 Typical Mechanical Options ScreenCustomer Setup Menu Figure 74 Typical Ethernet Setup ScreenUnits Figure 73 Typical Units ScreenAlarm Log Figure 75 Typical Alarm Flags & Feeder Setup ScreenFigure 76 Typical Alarm Log Screen Factory Default Setup Parameters BF1-615.3Chapter 7 6BAppendix 92 of93 of VIRGIN7-5 Mitsubishi Communications Manual Note ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITEGENERAL BLENDER INFO BLENDER STARTING AND STOPPINGBLENDER ALARMS INVENTORY INFO RECIPE INFO THIS IS WHERE YOU RIGHT THE NEW RECIPE TO CURRENT RECIPE INFO THIS IS THE RECIPE THAT IS CURRENTLY BEING MADETARGETS VS. ACTUAL WEIGHT INFO RECIPE BOOK MANIPULATIONAlarm Number Explanation FIXED DECIMAL EXPLANATIONRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH WRITING RECIPE EXPLANATIONUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH Service Department 7-6 Technical AssistanceParts Department Sales Department
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