System Component Description | Mitsubishi Electronics 882.00273.00

System Component Description

•Three (3) types of recipe entry procedures available:

oQuickset mode (up to 6-component) recipe entry. Color and additives are metered as a percentage of the virgin material.

oPercentage mode recipe entry. Ingredients are metered as a percentage of the overall batch.

oParts mode recipe entry (i.e. 500:1) Ingredients are metered as a ratio to each other within the batch

•Full control diagnostics

•Serial printer and RS-485 communications ports

System Component Description

This section describes the various components of the blending system.

Supply Hoppers

The material supply hoppers are located on top of the blender frame. These hoppers store a supply of material for the individual metering devices. They are sized based on the total throughput of the blender.

The blending system does not include any level indication devices on the unit. Optional low- level sensors are available. The blender controller will alarm if it runs out of material while trying to make a batch, but low-level sensors will alert floor personnel to the problem sooner.

Each hopper is equipped with a sight glass and/or access door.

Figure 5: Typical Hopper Assembly

BF1-615.3

Chapter 2: 1BFunctional Description

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Mitsubishi Electronics 882.00273.00 specifications System Component Description, Supply Hoppers, Typical Hopper Assembly

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 improvement Shipping Info Unpacking and InspectionIn the Event of Shipping Damage If the Shipment is Not Complete Warranty Returns Credit Returns Table of Contents CHAPTER 1 SAFETYCHAPTER 3 INSTALLATION CHAPTER 2 FUNCTIONAL DESCRIPTION CHAPTER 5 MAINTENANCE CHAPTER 6 TROUBLESHOOTINGCHAPTER 4 OPERATION CHAPTER 7 APPENDIX Hopper 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 Description 1-2 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 equipment General Responsibility 1-3 ResponsibilityOperator Responsibility REMEMBER Maintenance Responsibility Reporting a Safety Defect Accessories Customer ServiceChapter 2 Functional Description 2-1 Models Covered in This Manual Figure 2 Equipment Specifications Figure 3 Typical Blender AssemblyDimensions and Specifications 2500 2-3 Typical Features and Components Mechanical FeaturesController Features Figure 4 Typical Mitsubishi Controller Touch Screen Display System Component Description Figure 5 Typical Hopper AssemblySupply Hoppers Slide Gates Figure 6 Typical Slide Gate Assembly Weigh Hopper Figure 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 Function Figure 11 Typical Operator Screens 22 of Figure 12 Typical Setup Screens 23 of 24 of Figure 13 Mixer Slide Gate Switch Positions 2-4 Optional ComponentsPneumatic Slide Gate below Mixer Position Figure 15 Typical R.A.M. Hopper Blender Configuration Figure 16 Typical Additive Feeder ConfigurationRegrind Auger Metering R.A.M. Hopper Additive Feeder Hopper 2-5 Safety Features Safety Circuit StandardsSafety Device Lock-Outs Fail Safe Operation Twist 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 door Chapter 3 Installation 3-2 Mechanical Installation3-1 Uncrating the Equipment Figure 20 Blender Lifting Lugs 1 on each side Site 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 CUSTOMER Floor Mount Central Blender Figure 22 Typical Floor Mount Central Blender Layout 3-4 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 Limiters Weigh Hopper Installation Figure 25 Weigh HopperFinal Connections Figure 26 Display Startup Screen Figure 27 Display Main Recipe Screen Controller Set-up Blender 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 Instructions Alarm Setup Figure 30 Display Alarm Flags & Feeder Setup ScreenFeeder Calibration Auger Blenders Select a Feeder to Configure Change the Alarm Silence Delay Network Setup Figure 31 Ethernet Setup ScreenSetting Date and Time Figure 32 PanelView Configuration Screen Additional Setup Parameters 3-6 Initial Startup Quick Start Procedure Chapter 4 Operation4-1 Start-up General Operation Existing 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 Formats Recipe 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” mode Figure 38 Typical Batch Sizes BlenderBatch Size lbs Inventory Shutdown Auto Start Feature Mixer and Dump SetupMix Timer Figure 40 Typical Mixer and Dump Setup Operator Screen Weigh 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 Time Figure 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 Screen PLC 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 Screen Recipe Book Tree Diagram in section 3-5 of this manual Display Recipe Contents Figure 48 Typical Recipe Book Operator ScreenSave Running Recipe to the Book Load a Saved Recipe from the Book Erase Recipe or Entire Book Color Changes 4-3 Shut-down Figure 49 Typical Inventory Shutdown Operator Screen Chapter 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 Panel Output 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 action Problem Corrective action Problem warranty will be voided Service Department 7-1 Technical Specifications Equipment SpecificationsFigure 52 Equipment Specifications Chapter 7 Appendix Annex B Information Final Assembly 7-2 Drawings and DiagramsFigure 53 Typical Final Assembly Parts List Mixer Sub-Assembly 75 of Figure 54 Typical Mixer Assembly Parts List A0770319 Hopper Sub-assembly Figure 55 Typical Hopper Assembly Parts List Hopper R.A.M. Regrind Auger Metering Sub-Assembly Optional Figure 56 Typical R.A.M. Hopper Assembly Parts List Hopper Additive Feeder Sub-Assembly Optional Figure 57 Typical Additive Feeder Hopper Assembly Parts List Weigh Hopper Sub-assembly Figure 58 Typical Weigh Hopper Assembly Parts List Slide Gate Sub-assembly Figure 59 Typical Slidegate Assembly Parts List Knife Gate Sub-assembly HD Optional Figure 60 Typical Knife Gate below mixer Assembly Parts List Knife Gate Sub-assembly RD Optional Figure 61 Typical Knife Gate floor stand Assembly Parts List Figure 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 Kits 7-4 Addendum Service Supervisor Information PasswordsProgrammable Settings Figure 65 Typical Operator Setup Screen Figure 66 Typical Engineering Only Setup Screen Factory Setup MenuAdvanced Weight Options Screen Metering Test Screen Figure 68 Typical Advanced Weight Options Screen Feed Algorithm Options ScreenFigure 69 Typical Feed Algorithm Options Screen Feed Calibration Options Screen Feeder Setup Figure 72 Typical Feeder Setup ScreenMechanical Options Screen Figure 71 Typical Mechanical Options Screen Customer Setup Menu Figure 74 Typical Ethernet Setup ScreenUnits Figure 73 Typical Units Screen Alarm Log Figure 75 Typical Alarm Flags & Feeder Setup ScreenFigure 76 Typical Alarm Log Screen Factory Default Setup Parameters BF1-615.3Chapter 7 6BAppendix 92 of 93 of VIRGIN 7-5 Mitsubishi Communications Manual Note ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITEGENERAL BLENDER INFO BLENDER STARTING AND STOPPING BLENDER 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 MADE TARGETS VS. ACTUAL WEIGHT INFO RECIPE BOOK MANIPULATION Alarm Number Explanation FIXED DECIMAL EXPLANATION RECORDING 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