Mitsubishi Electronics 882.00273.00 specifications Problem, Corrective action

Page 68

 

Problem

 

 

Corrective action

 

 

 

 

 

Normal after a software upgrade. Follow on-screen instructions.

 

 

 

 

 

 

 

 

 

Check the input power. Verify that 110 volts (or 220 volts) are

 

 

 

 

±10%. This voltage must remain constant with all the motors

 

 

 

 

starting and stopping. Insure that the blender is on a “clean” circuit

 

 

 

 

that does not have other equipment on it. If the power is known to

 

 

 

 

be intermittent and have problems, set up the unit to run in

 

 

 

 

“AutoStart” mode. See the factory setup sheet at the end of this

 

 

 

 

manual. In this mode, if a short power interruption occurs, the

 

PLC Module Loaded

 

 

blender will automatically restart.

 

 

 

 

 

 

 

 

 

Check the power supply. Make sure that it has +5 VDC output to

 

 

 

 

 

 

 

 

the CPU board. Adjust to +5 VDC, ±0.1 volt.

 

 

 

 

 

 

 

 

 

 

Check the display ribbon cable connection to the CPU board and

 

 

 

 

the display. See the electrical chapter for more information.

 

 

 

 

 

 

 

 

 

Check the contrast adjustment located on the display board.

 

 

 

 

 

 

 

 

 

 

Check keyboard ribbon cable connections.

 

 

 

 

 

Check the CPU board for “lockup”. To do so, reset the CPU board

 

 

 

 

by cycling the power off and on at the motor control panel.

 

 

 

 

 

 

 

 

 

Check batch weight setting in the recipe menu. See the setup

 

 

 

 

chapter for more information.

 

 

 

 

 

 

 

 

 

 

Check the load cells and weigh hopper mounting for binding, etc.

 

 

 

 

 

 

Weigh hopper occasionally

 

 

Check to see that a pellet has not lodged under a load cell.

 

 

 

 

 

 

overfills.

 

 

Check the ingredient supply hoppers to verify proper ventilation. If

 

 

 

 

a vacuum receiver has a leaking flapper valve and the supply

 

 

 

 

hopper is not vented, the blender computer can learn inaccurately

 

 

 

 

and cause an overfill condition on the next few cycles.

 

 

 

 

 

 

 

 

 

 

Check the load cell connections to the panel.

 

 

 

 

 

 

 

 

 

 

Check the mix timer setting. This problem is normally due to over

 

 

 

 

mixing. See the mix timer section in the setup chapter. Reduce the

 

Material tends to separate in the

 

time until the problem is corrected.

 

 

mixing chamber.

 

 

Check the mixer drive to ensure that the agitator is turning

 

 

 

 

properly.

 

 

 

 

 

 

 

 

 

 

Check the high level switch in the mixer to lower the level slightly.

 

 

 

 

 

 

 

Material sticks to the flapper of

 

 

 

 

 

the weigh hopper and is not

 

 

Increase the Dump Cycles setting in Mixer and Dump Setup.

 

dumped.

 

 

 

 

 

 

 

 

 

 

 

Too much material remains in

 

 

Increase the Mixer Dump Time in Mixer and Dump Setup.

 

the mixer.

 

 

 

 

 

 

 

 

 

 

 

Increase the Mixing Time in Mixer and Dump Setup. Actually if

 

The material is not being mixed

 

you over mix material, you can have the same problem. If you

 

thoroughly.

 

 

have the blender set for “Continuous Mixing” then change it to

 

 

 

 

“Timed Mixing” and adjust the Mixing Time appropriately.

 

 

 

 

BF1-615.3

Chapter 6: 5BTroubleshooting

68 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 Safety Symbols Used in this Manual Chapter 1 Safety1-1 How to Use 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 equipmentOperator Responsibility 1-3 ResponsibilityGeneral 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 DisplaySupply Hoppers Figure 5 Typical Hopper AssemblySystem Component Description Slide Gates Figure 6 Typical Slide Gate Assembly Weigh HopperFigure 7 Typical Weigh Hopper Assembly Operator Control Panel Display Figure 8 Typical Mixer AssemblyMix Chamber 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 OperationFigure 18 Twist Cap Plug Figure 17 Electrical Disconnect PlugTwist Cap Plug Connected to Each Feeder Auger Motor 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 sideMachine Mount Mounting ConfigurationsSite Requirements 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 LayoutFigure 23 Customer-Supplied Pneumatic Components 3-3 Electrical Connections3-4 Pneumatic Connections 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 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 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 Delay Time Re-Mix TimerWeigh Hopper Dump 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 ScreenFigure 46 Typical “E-Stop Activated” Alarm Screen Figure 45 Typical “PLC Battery Low” Alarm ScreenPLC BATTERY LOW 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 PanelNote The alarm contact has a maximum load of 3 amps Input Signals to Programmable ControllerOutput Signals from Programmable Controller 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 Figure 53 Typical Final Assembly Parts List 7-2 Drawings and DiagramsFinal Assembly 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 ListControl Panel Layout Figure 62 Typical Mitsubishi Controller Main Parts ListFigure 63 Typical Mitsubishi Display Main Parts List 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 ScreenFigure 76 Typical Alarm Log Screen Figure 75 Typical Alarm Flags & Feeder Setup ScreenAlarm Log 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 EXPLANATIONUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH WRITING RECIPE EXPLANATIONRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH Service Department 7-6 Technical AssistanceParts Department Sales Department
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