SPC FLOOR Automatic Mixing System Instruction Manual Book

Content:

• Safety Instructions
• Mixer Unit（1300/4500）
• Pulse Dust Collector（VF3）
• Hot Mixing Inverter
• Attachment

Safety instructions

1.1 Instructions for use

The product use and maintenance instructions relate to the agreement between the company and the user regarding the rights and obligations of this product liability and after-sales service. Users must carefully read the instructions before using this product. Any improper operation and missing maintenance may cause product failure and damage, and even personal injury.

1.2 Mark

This manual uses the following marks in accordance with safety-related content.

A description of the security mark indicates important content, so be sure to follow it. In addition, even if it is a precaution, depending on the specifics, it may cause a major accident.

1.3 Safety Precautions

•  Equipment operation and maintenance personnel should read this manual carefully before using the machine.
• The operation of the equipment must be handled by a dedicated person, and the operator should fully understand the characteristics and performance of the equipment!
• Workers in production or maintenance must wear dust masks and goggles.
• Please observe the safety instructions marked on the device, do not block or write.
• When the power-on equipment is running, the body must be well grounded to prevent leakage!
• All equipment is strictly prohibited from stepping on, and stacking tools, sundries, etc.!
• When maintaining equipment with pneumatic or hydraulic mechanisms, the operator must ensure that the pressure inside the mechanism is fully unloaded before maintenance to prevent malfunction!

Safety Statement

• When the equipment fails, it is inspected and repaired by a professional.
• When there is a problem, please contact the manufacturer to solve it!
• When working on the production line, please observe the safety signs on the equipment.

Mixer unit（1300/4500A）

The hot and cold mixing unit is mainly used for mixing, coloring or drying of hygroscopic resins such as polyvinyl chloride resin, polyethylene, polypropylene, ABS, and polycarbonate，the material is mixed by hot mixing at high speed and then into cold mixing, then cooled and stirred to cool it to prevent degradation and agglomeration of the hot mixed material, so that the additives in the hot mixed material continue to infiltrate，the residual gas in the hot mixed material is excluded, and the hot mixed material can be stored, which has the characteristics of good mixing effect and fast cooling speed. The unit is stable, reliable, durable, easy to operate and compact. It can meet the requirements of plastic production process and is an ideal equipment for various plastic products industries.

2.1 The Main Technical Parameters

2.2 Main Structure and Working Principle

Outline drawing

Structural parameter table                                                                                                                                                                     Unit：mm

Working Principle

The horizontal cold and hot mixing unit is composed of a high-speed mixer and a cooling mixer. The high-speed mixer is equipped with three mixing blades and guide plates. Under its action, the materials make complex movements such as high-speed rotation and turning, so that the temperature can rise rapidly and meet the requirements of the material mixing process. Then, the materials enter the cooling mixer. Through the heat exchange between the low-speed operation of the mixing blades and the cooling device, the materials can be cooled rapidly and meet the requirements of the production process. Its structural features are as follows:

The unit consists of seven parts: frame, transmission, pot body, pot cover, lifting, discharging port and electrical control cabinet. The whole machine adopts closed structure, and the compact arrangement of high-speed mixer and cooling mixer saves space position.

The pot body is made of stainless steel, the inner surface is very hard, smooth, wear-resistant, corrosion-resistant and not easy to stick. The hot mix jacket is covered with a heat preservation layer. The pot body of the cooling mixer is provided with a cooling jacket, which can achieve the effect of cooling materials through cooling water circulation.

The pot cover of high-speed mixer is made of aluminum alloy. The inner surface is finished and polished. After it is lifted by the cylinder, it can rotate horizontally and clockwise along the vertical rotation axis. The pot cover is provided with resin, plasticizer, stabilizer liquid feeding hole and vent hole, which can be arranged by users according to their own needs. In order to prevent personal accidents caused by the rotation of mixing slurry when the pot cover is not properly covered, a travel switch is set on the pot body. When the pot cover is not tightly covered, the switch is not connected and the motor cannot be started. The lifting and lowering of the pot cover of the cooling mixer is controlled by the air cylinder or manually, and the materials are cooled by circulating water.

The guide plate of high-speed mixer can enhance the mixing effect. The guide plate has a streamlined surface, which affects the circulation of materials. The thermocouple is assembled on the wall of the boiler, its connecting line is led out and connected to the temperature instrument of the electric control box. The material temperature can be read out from the indicating instrument, which is used to automatically or manually control the discharge of the discharge port.

The main shaft and mixing slurry of high-speed mixer are driven by motor via V-belt wheel. The motor is AC double speed motor. As long as the low and high-speed buttons are pressed, the low and high-speed conversion can be realized. However, it must be noted that if high-speed operation is required, the motor shall be started stably at low speed before turning to high-speed operation. The main shaft is supported by deep groove ball bearing.

There are three agitated pulps on the upper part of the main shaft, which rotate clockwise to make the materials move along the wall of the boiler, and at the same time rotate up and down. With the function of the guide plate, the mixing effect is better. Because the materials move at a high speed, the friction heat between the particles, between the materials and the pulp leaves is very large, which makes the material temperature rise rapidly, and is conducive to the absorption effect of the resin on the plasticizer. The agitated slurry is made of stainless steel and has good wear and corrosion resistance after machining and polishing.

The driving part of the cooling mixer is driven by the motor belt to drive the reducer, which drives the mixing slurry on the main shaft to rotate, so as to cool and mix the hot mixed materials. The adjustable lead screw is set in the frame, which can adjust the tightness of the transmission triangle belt, open the door cover to replace the triangle belt, fix the motor base, repair and maintenance.

The main shaft sealing device of the equipment is composed of four oil seals. The sealing chamber is equipped with air blowing device, which can prevent material leakage and cool the main shaft. The gas volume shall be controlled by the user through the gas volume regulating valve, and the gas volume regulation shall be appropriate..（See Figure 2）

The discharge part is cast from an aluminum alloy. Each is equipped with a pneumatic discharge door, which is connected by the cylinder and the material door in one line, with reliable compression, good sealing performance and flexible opening and closing. Use one 0.39~0.49Mpa air compressor (selected by the user). The opening and closing of the discharge door can be controlled by the automatic control of the material temperature in the pot and the manual operation of the button.（See Figure 3）

The electrical control system consists of four parts, namely the hot mix motor control part, the cold mix motor control part, the hot mix discharge control part and the cold mix discharge control part. Please refer to the electrical schematic for the specific control principle.

The Electrical control system operation steps are as follows:

• Check if the system cooling water inlet pressure meets the requirements；
• Check if the system air supply pressure meets the requirements；
• Close the circuit breaker inside the control cabinet and turn on the power；
• Set system parameters before powering on：

a. Set hot mix time（Time relay KT1, the initial time is generally set at 15 minutes, this time to participate in the hot mix discharge control to be adjusted with the mixing work process）;

b. Set hot mix automatic unloading time（Time relay KT2, generally set time is 90 seconds, this time not only ensures that the hot mixing can completely discharge the material, but also allows the heat to mix for a cooling time）；

c. Set cold mixing automatic unloading time（Time relay KT3, generally set time     is 90 seconds, this time setting can not affect hot mix and discharge）；

d. According to the process requirements, set the material temperature during hot mixing and automatic unloading（Temperature control table ST1, please read the temperature control table operation manual carefully before adjustment）；

e. According to the process requirements, set the temperature of the material when cold mixing is automatically discharged.（Temperature control table ST2, please read the temperature control table operation manual carefully before adjustment）；

• The hot mix motor starts. Start the hot-mixed motor at a low speed first, and then start the motor at a low speed and then start at a high speed
• Starting the cold mix motor before the hot mix discharge
• Hot mix control

e. Manual operation: When the hot mix is manually controlled (the hot mix control is placed in the “manual” position), If you need to unload the hot mix,   press the hot mix manual discharge button; if you need to close the discharge   valve, press the hot mix manual discharge stop button；

f. Automatic operation：When the system is running automatically (the hot  mix and discharge control is placed in the “automatic” position), when the temperature of the hot mixed material reaches the set value (generally PV-SV ≥ 2), the temperature control table outputs the signal, hot mix Discharge valve automatically opens；The hot mix discharge valve automatically closes after the discharge time has reached the set time.

g. Automatic Operation 2：When the system is running automatically (the hot  mix control is placed in the “auto” position), the control system can time the hot mix process. The signal K in the electronic control system is the time control start signal of the hot mix and discharge valve (see electrical schematic). If this signal is not available, the signal K can be short-circuited at both ends. However, after the hot-mixing and discharging is completed, the hot-mixing control button must be switched from the “manual” position to the “automatic” position again to regain the timing unloading. Material function.

• Cold Mix Discharge Control：

a. Manual Operation：When the cold mix and discharge is manually controlled (the cold mix discharge control is placed in the “manual” position), if the cold mix is to be unloaded, press the cold mix manual discharge button；To close the discharge valve, press the cold mix manual discharge stop button；

b. Automatic operation：When the system is running automatically（Cold mix discharge control is placed in the “automatic” position），When the temperature of the cold mixed material is lower than the set value (in general, it should be SV-PV≥2), the temperature control table outputs the signal, and the hot and cold mixing and discharging valve is automatically opened；After the discharge time reaches the set time, the cold mix discharge valve closes automatically；

• Parking operation

When the mixing unit needs to stop working, the material in the mixing unit should be removed first, then the main motor should be stopped, and finally the power switch should be disconnected；

•  Hot mix lid control：（Manual air valve at the mixing unit site）

a. Disconnect the power switch of the electronic control system；

b. Loosen the fastening handle on the hot mix lid；

c. Operate the manual control valve to control the lifting of the lid.After the hot mix lid is raised, the hot mix lid limit switch is released and the hot mix motor control loop is disconnected

d. To exit the hot mix lid control, first return the hot mix lid to the bottom and then tighten the handle.

If the hot mixing pot lid is not closed, there may be cases where the hot mixing pot lid limit switch is not closed or closed. The former makes the hot-mixed motor unable to start, and the latter easily causes damage to the electrical components of the electronic control system.

• Cold mix lid control：（Manual air valve at the mixing unit site）a. Disconnect the power switch of the electronic control system；

a. Loosen the fastening handle on the cold mixer lid；

b. Operate the manual control valve to control the lifting of the lid. After the  cold mix pan is raised, the cold mix pan cover limit switch is released and the cold mix motor control circuit is disconnected.

c. To exit the cold mix lid control, first return the cold mix pan cover to the  end, then tighten the handle. If the cold mixing pot lid is not closed, there may be cases where the cold mixing pot lid limit switch is not closed or closed. The former makes the cold mixing motor unable to start, and the latter is likely to cause damage to the electrical components of the electronic control system.

PS：When the mixing unit is in the automatic unloading state, if the unloading part of the system fails, the unloading valve will not open even if the unloading condition of the mixer discharge valve is satisfied. At this point, the user should perform a parking operation, unload the material, and repair it.

1.3 Installation and commissioning and lifting diagram

Main process

• The equipment is installed on the first floor.（Reference layout）
• Check that the field equipment and parts are complete.
• Check that the basis provided by the customer matches the drawing.
• According to the layout diagram and the basic diagram, determine the on-site installation centerline.

• The customer installs the pre-embedded bolts in the set position as required.
• The shelves of the hot mixer and the cold mixer are respectively fixed at the position of the embedded bolt.
• After installation, check whether the power supply, air source, etc. are consistent with the requirements of the machine, and check whether there is any error in the circuit according to the electrical schematic.
• Each lubricating point should be filled with the specified lubricating oil (fat) as required, and the anti-rust oil in the rack should be cleaned.
• Commissioning requirements

Lifting diagram Use and maintenance

Mixer unit lifting lug position：

1.4  Use and maintenance

• Check the equipment regularly and make a record of the inspection. Check for looseness of each coupling bolt.
• Do a good job of sanitation around the equipment every day to improve the operating environment of the equipment.
• Equipment maintenance and repair needs to be disconnected from the power supply and listed for warning. After the overhaul is completed, all maintenance personnel should be notified to close the door.

Matters needing attention:

1．This unit is not allowed to start with load and frequent start. It should be operated normally before feeding, and the discharge should not stop.

2．When the lid is pressed, the lifting device is not allowed to prevent deformation or damage of the lid.

3．The pressure of the cooling water in the mixer should be strictly controlled within the technical parameters to prevent deformation or leakage of the cooling ring.

Vulnerable parts list

3. Pulse Dust Collector（VF3）

3.1  The main technical parameters 

    VF3:

Equipment size                     350X350X1250 mm;

Equipment weight                  30KG

Filter material                      PTFE Coated polyester non-woven fabric

Shell material                      Stainless steel SS304；δ=2mm

Use                              With fan, exhaust special

VF– pulse dust collector

4– housing diameter =400，            unit: mm

3.2  Main structure and working principle

The main structure：

1. Exhaust fan（1.5KW）； 2. Pulse chamber； 3. Pulse solenoid valve； 4. Air bag； 5. Filter element； 6. Dust chamber.

Main working principle：

The pulse filter generally has two chambers of a pulse chamber and a dust remover, and a filter element is arranged in the middle, and the exhaust fan generates a pressure difference between the two chambers，When the gas drives the powder out of the pulse chamber, the large particle powder is separated by the filter element and falls into the dust chamber, and the small particles are adsorbed on the surface of the filter element. As the filtration is performed, the small particles of powder on the filter element accumulate and the airflow assists.There is a pulse valve in the pulse chamber, the time value is set by the PLC, and the compressed air back-blowing filter element is controlled regularly to play the function of automatically cleaning the filter element, so that the small particle powder falls into the dust chamber.

3.3  Installation and commissioning and lifting diagram

The main process：

• The equipment is installed in the upper part of the auxiliary material dumping station.
• Check the field equipment components and complete.
• All fasteners are securely fastened.
• The trachea and cable are arranged reasonably and beautifully.
• Debug the device after everything is in place.
• Commissioning requirements.

Equipment lifting diagram：

3.4  Use and maintenance of SPC FLOOR Automatic Mixing System

• Check the equipment every day and make a good inspection record. Check if the connecting bolts and pulse solenoid valves are loose.
• Do a good job of sanitation around the equipment every day to improve the operating environment of the equipment.
• Dust masks and goggles must be worn before working or servicing.
• Equipment maintenance and repair needs to be disconnected from the power supply and listed for warning. After the overhaul is completed, all maintenance personnel should be notified to close the door.
• The dust filter element is a wearing part. Check it regularly for half a year. Observe the condition of the surface filter cover. Clean it as needed. Remove the filter element once a year, or replace it completely.
• Fault and its solution

Vulnerable list  

• Frequency converter

  See the purchased manual for details.

• Mixing Unit Instruction Manual File (Click to read it)

Mixing System Instruction.pdf