Mitsubishi Electronics 882.00273.00 Mitsubishi Communications Manual, General Blender Info

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7-5 Mitsubishi Communications Manual

The Mitsubishi blender uses a FX-2N processor that communicates with the outside world using MELSEC FX protocol over Ethernet hardware. It’s Ethernet speed is 10 Mbits/second. The blender must be purchased from ACS with the Ethernet option. If this was not done at the time of purchase it can be added afterwards by consulting the factory. The blender has a programmable IP address and subnet mask that can be programmed from software that is provided by DIGI for the Ethernet module (refer to their manual).

Ethernet is the standard that we support, but Mitsubishi also supports Profibus and MELSEC Serial communications. Refer to Mitsubishi for parts and information.

The communications port settings on the PLC are: 19,200 baud; 8 data bits; no parity;1 stop bit; software flow control.

The communications must also be enabled. From the main screen touch the “next” button to go to the “inventory” page. Touch “Log in” and type in “5413”. Then touch the “ACS logo” and this will take you to setup. Touch the “Network Setup” button and ensure that communications is enabled. If it wasn’t then you’ll need to change it and then reboot the PLC for it to take effect. The Ethernet module takes about 45 seconds to regain communications upon boot.

Below are the items that can be accessed for the blender:

Note: ITEMS MARKED (R) ARE READ ONLY AND ITEMS MARKED (RW) ARE READ/WRITE

GENERAL BLENDER INFO

1(R) plc_version,D1942,SHORT VALUE (xx.x)

2(R) number_of_hoppers,D1702,SHORT VALUE (number of hoppers on the blender)

3(R) maximum_blender_throughput,D1056,LONG VALUE(maximum rate blender can achieve)

4(R) average_batch_time, D1938,SHORT VALUE (average amount of time it takes to finish the batch)

5(R) average_process_rate,D1334,LONG VALUE (average rate at which the process is consuming blended material)

BLENDER STARTING AND STOPPING

1(R) blender_started,M500

2(RW) blender_start_request,M540 (toggle this to start or stop the blender, blender will switch it’s current status, you must also reset this bit after completion)

3(RW) abort_batch_request,M508 (toggle this to immediately stop the blender even if the batch is incomplete, you must also reset this bit after completion)

BF1-615.3

Chapter 7: 6BAppendix

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Contents Part Number Bulletin Number BF1-615.3 Effective 11/07/07 Write Down Your Serial Numbers Here For Future ReferenceGravimetric Slide Gate Batch Blender Mitsubishi Controller We are committed to a continuing program of product improvementIn the Event of Shipping Damage Shipping InfoUnpacking and Inspection If the Shipment is Not CompleteWarranty Returns Credit ReturnsCHAPTER 3 INSTALLATION Table of ContentsCHAPTER 1 SAFETY CHAPTER 2 FUNCTIONAL DESCRIPTIONCHAPTER 4 OPERATION CHAPTER 5 MAINTENANCECHAPTER 6 TROUBLESHOOTING CHAPTER 7 APPENDIXHopper 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 DescriptionWear SAFETY GLASSES and WORK GLOVES 1-2 Warnings and PrecautionsCAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipmentGeneral Responsibility 1-3 ResponsibilityOperator Responsibility REMEMBER Maintenance Responsibility Reporting a Safety DefectChapter 2 Functional Description AccessoriesCustomer Service 2-1 Models Covered in This ManualDimensions and Specifications Figure 2 Equipment SpecificationsFigure 3 Typical Blender Assembly 2500Controller Features 2-3 Typical Features and ComponentsMechanical Features Figure 4 Typical Mitsubishi Controller Touch Screen DisplaySystem Component Description Figure 5 Typical Hopper AssemblySupply Hoppers Slide Gates Figure 6 Typical Slide Gate Assembly Weigh HopperFigure 7 Typical Weigh Hopper Assembly Mix Chamber Figure 8 Typical Mixer AssemblyOperator Control Panel Display Button Figure 9 Typical Mitsubishi Controller Touch Screen DisplayFigure 10 Controller Pushbuttons & Touchscreen Tags FunctionFigure 11 Typical Operator Screens 22 ofFigure 12 Typical Setup Screens 23 of24 of Pneumatic Slide Gate below Mixer Figure 13 Mixer Slide Gate Switch Positions2-4 Optional Components PositionRegrind Auger Metering R.A.M. Hopper Figure 15 Typical R.A.M. Hopper Blender ConfigurationFigure 16 Typical Additive Feeder Configuration Additive Feeder HopperSafety Device Lock-Outs 2-5 Safety FeaturesSafety Circuit Standards Fail Safe OperationTwist 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 door3-1 Uncrating the Equipment Chapter 3 Installation3-2 Mechanical Installation Figure 20 Blender Lifting Lugs 1 on each sideSite Requirements Mounting ConfigurationsMachine Mount Figure 21 Typical Mezzanine Mounted Batch Blender Note Larger blenders need to be braced as part of the installationMezzanine Mount GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMERFloor Mount Central Blender Figure 22 Typical Floor Mount Central Blender Layout3-4 Pneumatic Connections 3-3 Electrical ConnectionsFigure 23 Customer-Supplied Pneumatic Components Stroke Limiters for Metering Gates 3-5 Initial Set-upMechanical Set-up Figure 24 Stroke LimitersFinal Connections Weigh Hopper InstallationFigure 25 Weigh Hopper Figure 26 Display Startup ScreenFigure 27 Display Main Recipe Screen Controller Set-upBlender Controller Menu Structure Blender Calibration Enter in the Calibration Weight Press here to perform the calibration Figure 28 Display Calibration Menu ScreenFigure 29 Display Calibration Screen Current Loadcell Bits Follow InstructionsFeeder Calibration Auger Blenders Alarm SetupFigure 30 Display Alarm Flags & Feeder Setup Screen Select a Feeder to Configure Change the Alarm Silence DelaySetting Date and Time Network SetupFigure 31 Ethernet Setup Screen Figure 32 PanelView Configuration ScreenAdditional Setup Parameters 3-6 Initial Startup 4-1 Start-up Quick Start ProcedureChapter 4 Operation General OperationExisting 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 FormatsRecipe Format Menu “Quickset” Mode Most common in injection molding Page “Percentage” Mode Most common in extrusion and blow molding Switching ModesRecipe Setup Figure 37 Example Calculations of a 4-component blend in “Parts” modeBatch Size lbs Figure 38 Typical Batch SizesBlender Inventory ShutdownMix Timer Auto Start FeatureMixer and Dump Setup Figure 40 Typical Mixer and Dump Setup Operator ScreenWeigh Hopper Dump Time Re-Mix TimerWeigh Hopper Dump Delay Time Weigh Hopper Dump Cycle Alarm FlagsFigure 41 Typical “Out of Material” Alarm Screen Mixer Dump TimeFigure 43 Typical “Calibration Error” Alarm Screen Figure 42 Typical “Maximum Hopper Weight” Alarm ScreenMAX HOPPER WEIGHT EXCEEDED check batch size Figure 44 Typical “Power Interruption” Alarm ScreenPLC 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 ScreenRecipe Book Tree Diagram in section 3-5 of this manualSave Running Recipe to the Book Display Recipe ContentsFigure 48 Typical Recipe Book Operator Screen Load a Saved Recipe from the BookErase Recipe or Entire Book Color Changes4-3 Shut-down Figure 49 Typical Inventory Shutdown Operator ScreenFigure 50 Sample Preventative Maintenance Schedule Chapter 5 Maintenance5-1 Preventative Maintenance Schedule System model #Electrical 5-2 Preventative Maintenance5-3 Corrective Maintenance Internal Components of the Control PanelOutput Signals from Programmable Controller Input Signals to Programmable ControllerNote The alarm contact has a maximum load of 3 amps 6-1 Introduction Chapter 6 TroubleshootingProblem Corrective actionProblem Corrective actionProblem warranty will be voided Service Department Figure 52 Equipment Specifications 7-1 Technical SpecificationsEquipment Specifications Chapter 7 AppendixAnnex B Information Final Assembly 7-2 Drawings and DiagramsFigure 53 Typical Final Assembly Parts List 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 ListFigure 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 KitsProgrammable Settings 7-4 Addendum Service Supervisor InformationPasswords Figure 65 Typical Operator Setup ScreenAdvanced Weight Options Screen Figure 66 Typical Engineering Only Setup ScreenFactory Setup Menu Metering Test ScreenFigure 69 Typical Feed Algorithm Options Screen Figure 68 Typical Advanced Weight Options ScreenFeed Algorithm Options Screen Feed Calibration Options ScreenMechanical Options Screen Feeder SetupFigure 72 Typical Feeder Setup Screen Figure 71 Typical Mechanical Options ScreenUnits Customer Setup MenuFigure 74 Typical Ethernet Setup Screen Figure 73 Typical Units ScreenAlarm Log Figure 75 Typical Alarm Flags & Feeder Setup ScreenFigure 76 Typical Alarm Log Screen Chapter 7 6BAppendix Factory Default Setup ParametersBF1-615.3 92 of93 of VIRGINGENERAL BLENDER INFO 7-5 Mitsubishi Communications ManualNote ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITE 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 EXPLANATIONRECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH WRITING RECIPE EXPLANATIONUNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH Parts Department Service Department7-6 Technical Assistance Sales Department