Mitsubishi Electronics 882.00273.00 specifications Service Department, Problem, Corrective action

Page 71

 

Problem

 

 

Corrective action

 

 

 

 

 

This Is caused by the difference in bits not being large enough.

 

I can’t calibrate the Scale

 

 

Using the Direct Scale Readout, examine current loadcell bits with

 

 

 

and without the calibration weight. If the bits do not change

 

without an error message.

 

 

 

 

 

significantly, then check for pellets jamming the loadcells and

 

 

 

 

 

 

 

 

check the loadcell circuit. You might have a bad loadcell.

 

 

 

 

 

 

 

 

 

Do other feeders calibrate correctly? Is the feeder I’m trying to

 

 

 

 

calibrate a large gate? If these are true, then lower the Batch % for

 

 

 

 

Feeder Cal setting under Feed Calibration Options. This can be

 

I can’t calibrate the feeder

 

 

observed by looking at the Hopper Weight display.

 

without an error message.

 

 

 

 

 

 

 

None of the feeders calibrate? Check the Scale Calibration. If this

 

 

 

 

 

 

 

 

is correct, then lower the Batch% for Feeder Cal setting under Feed

 

 

 

 

Calibration Options for each feeder. This can be observed by

 

 

 

 

looking at the Hopper Weight display.

 

 

 

 

 

 

 

 

 

 

Check the dump time setting. It may be set too short.

 

Weigh hopper does not empty

 

 

If this does not correct the problem, clean the weigh hopper and

 

completely.

 

 

recheck the scale diagnostics readout. If not showing (0) zero when

 

 

 

 

empty, re-calibrate the scale.

 

 

 

 

 

 

 

 

 

 

Verify application is not exceeding blender capacity.

 

 

 

 

Verify additive percentage is not higher than designed, resulting in

 

Blender does not make rate.

 

 

excessive dispense time.

 

 

 

 

 

Verify all materials are feeding freely through the metering gates

 

 

 

 

or augers.

 

 

 

 

 

 

 

 

I have changed the recipe entry

 

 

All of these settings are part of the current running recipe. This

 

mode, metering order, batch

 

 

 

 

 

makes it easy for the operator to load a stored recipe without

 

size, inventory shutdown,

 

 

 

 

 

having to reconfigure all of these parameters for the new recipe.

 

weigh every batch mode, or

 

 

 

 

 

All you have to do is touch “Accept New Recipe” to load these

 

feeder type and alarm flags, but

 

 

 

 

 

values into the running recipe.

 

 

the change hasn’t taken place.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A feeder always puts too much

 

 

Check that the Gate Cycle Time is set correctly. If it is then lower

 

 

 

the Initial % of Target to Meter. These are found under Feed

 

material in the batch.

 

 

 

 

 

Algorithm Options. Make small adjustments and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

Increase the Gate Cycle Time. This is found under Feed

 

A feeder is retrying more than

 

 

Algorithm Options. Make small adjustments and retest.

 

 

 

 

 

 

 

 

Increase the Allowed Underfeed value under Feed Algorithm

 

2-4 times.

 

 

 

 

 

Options.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Decrease the Retries before Double Gate Time.

 

 

 

 

 

Note: Other service problems or questions can be answered by contacting the

 

Service Department.

 

BF1-615.3

Chapter 6: 5BTroubleshooting

71 of 101

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Contents We are committed to a continuing program of product improvement Write Down Your Serial Numbers Here For Future ReferenceGravimetric Slide Gate Batch Blender Mitsubishi Controller Part Number Bulletin Number BF1-615.3 Effective 11/07/07If the Shipment is Not Complete Shipping InfoUnpacking and Inspection In the Event of Shipping DamageCredit Returns Warranty ReturnsCHAPTER 2 FUNCTIONAL DESCRIPTION Table of ContentsCHAPTER 1 SAFETY CHAPTER 3 INSTALLATIONCHAPTER 7 APPENDIX CHAPTER 5 MAINTENANCECHAPTER 6 TROUBLESHOOTING CHAPTER 4 OPERATIONHopper 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 LabelsUse care when LOADING, UNLOADING, RIGGING, or MOVING this equipment 1-2 Warnings and PrecautionsCAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVESOperator Responsibility 1-3 ResponsibilityGeneral Responsibility REMEMBER Reporting a Safety Defect Maintenance Responsibility2-1 Models Covered in This Manual AccessoriesCustomer Service Chapter 2 Functional Description2500 Figure 2 Equipment SpecificationsFigure 3 Typical Blender Assembly Dimensions and SpecificationsFigure 4 Typical Mitsubishi Controller Touch Screen Display 2-3 Typical Features and ComponentsMechanical Features Controller FeaturesSupply 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 Function Figure 9 Typical Mitsubishi Controller Touch Screen DisplayFigure 10 Controller Pushbuttons & Touchscreen Tags Button22 of Figure 11 Typical Operator Screens23 of Figure 12 Typical Setup Screens24 of Position Figure 13 Mixer Slide Gate Switch Positions2-4 Optional Components Pneumatic Slide Gate below MixerAdditive Feeder Hopper Figure 15 Typical R.A.M. Hopper Blender ConfigurationFigure 16 Typical Additive Feeder Configuration Regrind Auger Metering R.A.M. HopperFail Safe Operation 2-5 Safety FeaturesSafety Circuit Standards Safety Device Lock-OutsFigure 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 SwitchFigure 20 Blender Lifting Lugs 1 on each side Chapter 3 Installation3-2 Mechanical Installation 3-1 Uncrating the EquipmentMachine Mount Mounting ConfigurationsSite Requirements GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMER Note Larger blenders need to be braced as part of the installationMezzanine Mount Figure 21 Typical Mezzanine Mounted Batch BlenderFigure 22 Typical Floor Mount Central Blender Layout Floor Mount Central BlenderFigure 23 Customer-Supplied Pneumatic Components 3-3 Electrical Connections3-4 Pneumatic Connections Figure 24 Stroke Limiters 3-5 Initial Set-upMechanical Set-up Stroke Limiters for Metering GatesFigure 26 Display Startup Screen Weigh Hopper InstallationFigure 25 Weigh Hopper Final ConnectionsController Set-up Figure 27 Display Main Recipe ScreenBlender Controller Menu Structure Blender Calibration Current Loadcell Bits Follow Instructions Figure 28 Display Calibration Menu ScreenFigure 29 Display Calibration Screen Enter in the Calibration Weight Press here to perform the calibrationSelect a Feeder to Configure Change the Alarm Silence Delay Alarm SetupFigure 30 Display Alarm Flags & Feeder Setup Screen Feeder Calibration Auger BlendersFigure 32 PanelView Configuration Screen Network SetupFigure 31 Ethernet Setup Screen Setting Date and TimeAdditional Setup Parameters 3-6 Initial Startup General Operation Quick Start ProcedureChapter 4 Operation 4-1 Start-upNote 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 Figure 37 Example Calculations of a 4-component blend in “Parts” mode Switching ModesRecipe Setup “Percentage” Mode Most common in extrusion and blow moldingInventory Shutdown Figure 38 Typical Batch SizesBlender Batch Size lbsFigure 40 Typical Mixer and Dump Setup Operator Screen Auto Start FeatureMixer and Dump Setup Mix TimerWeigh Hopper Dump Delay Time Re-Mix TimerWeigh Hopper Dump Time Mixer Dump Time Alarm FlagsFigure 41 Typical “Out of Material” Alarm Screen Weigh Hopper Dump CycleFigure 44 Typical “Power Interruption” Alarm Screen Figure 42 Typical “Maximum Hopper Weight” Alarm ScreenMAX HOPPER WEIGHT EXCEEDED check batch size Figure 43 Typical “Calibration Error” 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 BookLoad a Saved Recipe from the Book Display Recipe ContentsFigure 48 Typical Recipe Book Operator Screen Save Running Recipe to the BookColor Changes Erase Recipe or Entire BookFigure 49 Typical Inventory Shutdown Operator Screen 4-3 Shut-downSystem model # Chapter 5 Maintenance5-1 Preventative Maintenance Schedule Figure 50 Sample Preventative Maintenance ScheduleInternal Components of the Control Panel 5-2 Preventative Maintenance5-3 Corrective Maintenance ElectricalNote The alarm contact has a maximum load of 3 amps Input Signals to Programmable ControllerOutput Signals from Programmable Controller Corrective action Chapter 6 TroubleshootingProblem 6-1 IntroductionCorrective action ProblemCorrective action warranty will be voided Service Department Chapter 7 Appendix 7-1 Technical SpecificationsEquipment Specifications Figure 52 Equipment SpecificationsAnnex 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 ListingFigure 65 Typical Operator Setup Screen 7-4 Addendum Service Supervisor InformationPasswords Programmable SettingsMetering Test Screen Figure 66 Typical Engineering Only Setup ScreenFactory Setup Menu Advanced Weight Options ScreenFeed Calibration Options Screen Figure 68 Typical Advanced Weight Options ScreenFeed Algorithm Options Screen Figure 69 Typical Feed Algorithm Options ScreenFigure 71 Typical Mechanical Options Screen Feeder SetupFigure 72 Typical Feeder Setup Screen Mechanical Options ScreenFigure 73 Typical Units Screen Customer Setup MenuFigure 74 Typical Ethernet Setup Screen UnitsFigure 76 Typical Alarm Log Screen Figure 75 Typical Alarm Flags & Feeder Setup ScreenAlarm Log 92 of Factory Default Setup ParametersBF1-615.3 Chapter 7 6BAppendixVIRGIN 93 ofBLENDER STARTING AND STOPPING 7-5 Mitsubishi Communications ManualNote ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITE GENERAL BLENDER INFOBLENDER 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 Sales Department Service Department7-6 Technical Assistance Parts Department
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