Mitsubishi Electronics 882.00273.00 Technical Assistance, Parts Department, Service Department

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7-6 Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [810] 720-7300; Fax [810] 720-2598

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 423-3183 or call [810] 720-7300

Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most of our products.

www.acscustomerservice.com

Sales Department

Call [810] 720-7300 Monday–Friday, 8am–5pm CST

Our products are sold by a world-wide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.

Contract Department

Call [810] 720-7300 Monday–Friday, 8am–5pm CST

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.

BF1-615.3

Chapter 7: 6BAppendix

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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 Safety Symbols Used in this Manual Chapter 1 Safety1-1 How to Use 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 equipmentOperator Responsibility 1-3 ResponsibilityGeneral 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 DisplaySupply 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 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 OperationFigure 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 Switch3-2 Mechanical Installation Chapter 3 Installation3-1 Uncrating the Equipment Figure 20 Blender Lifting Lugs 1 on each sideMachine Mount Mounting ConfigurationsSite Requirements 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 BlenderFigure 23 Customer-Supplied Pneumatic Components 3-3 Electrical Connections3-4 Pneumatic Connections 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 OperationNote 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 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 Delay Time Re-Mix TimerWeigh Hopper Dump 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 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 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 PanelNote The alarm contact has a maximum load of 3 amps Input Signals to Programmable ControllerOutput Signals from Programmable Controller 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 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 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 ScreenFigure 76 Typical Alarm Log Screen Figure 75 Typical Alarm Flags & Feeder Setup ScreenAlarm Log 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 ExplanationUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH WRITING RECIPE EXPLANATIONRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH 7-6 Technical Assistance Service DepartmentParts Department Sales Department