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882.00273.00 specifications BF1-615.3, 1BFunctional Description, 24 of
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Troubleshooting
Specification
Install
Parts list
Tree Diagram in -5 of this manual
Warranty
Maintenance
Typical R.A.M. Hopper Blender Configuration
Problem
Typical Setup Screens
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BF1-615.3
Chapter 2: 1BFunctional Description
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Contents
Write Down Your Serial Numbers Here For Future Reference
Gravimetric Slide Gate Batch Blender Mitsubishi Controller
Part Number Bulletin Number BF1-615.3 Effective 11/07/07
We are committed to a continuing program of product improvement
Shipping Info
Unpacking and Inspection
In the Event of Shipping Damage
If the Shipment is Not Complete
Warranty Returns
Credit Returns
Table of Contents
CHAPTER 1 SAFETY
CHAPTER 3 INSTALLATION
CHAPTER 2 FUNCTIONAL DESCRIPTION
CHAPTER 5 MAINTENANCE
CHAPTER 6 TROUBLESHOOTING
CHAPTER 4 OPERATION
CHAPTER 7 APPENDIX
Hopper Additive Feeder Sub-Assembly Optional
Chapter 1 Safety
1-1 How to Use This Manual
Safety Symbols Used in this Manual
Figure 1 Safety Tags and Warning Labels
Description
Description
1-2 Warnings and Precautions
CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON
Wear SAFETY GLASSES and WORK GLOVES
Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment
1-3 Responsibility
General Responsibility
Operator Responsibility
REMEMBER
Maintenance Responsibility
Reporting a Safety Defect
Accessories
Customer Service
Chapter 2 Functional Description
2-1 Models Covered in This Manual
Figure 2 Equipment Specifications
Figure 3 Typical Blender Assembly
Dimensions and Specifications
2500
2-3 Typical Features and Components
Mechanical Features
Controller Features
Figure 4 Typical Mitsubishi Controller Touch Screen Display
Figure 5 Typical Hopper Assembly
System Component Description
Supply Hoppers
Slide Gates
Figure 6 Typical Slide Gate Assembly
Weigh Hopper
Figure 7 Typical Weigh Hopper Assembly
Figure 8 Typical Mixer Assembly
Mix Chamber
Operator Control Panel Display
Figure 9 Typical Mitsubishi Controller Touch Screen Display
Figure 10 Controller Pushbuttons & Touchscreen Tags
Button
Function
Figure 11 Typical Operator Screens
BF1-615.3
Chapter 2 1BFunctional Description
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Figure 12 Typical Setup Screens
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Chapter 2 1BFunctional Description
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Chapter 2 1BFunctional Description
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Figure 13 Mixer Slide Gate Switch Positions
2-4 Optional Components
Pneumatic Slide Gate below Mixer
Position
Figure 15 Typical R.A.M. Hopper Blender Configuration
Figure 16 Typical Additive Feeder Configuration
Regrind Auger Metering R.A.M. Hopper
Additive Feeder Hopper
2-5 Safety Features
Safety Circuit Standards
Safety Device Lock-Outs
Fail Safe Operation
Figure 17 Electrical Disconnect Plug
Twist Cap Plug Connected to Each Feeder Auger Motor
Figure 18 Twist Cap Plug
Electric Safety Interlock Switch
Figure 19 Electrical Safety Interlock Switch Located on mixer door
Chapter 3 Installation
3-2 Mechanical Installation
3-1 Uncrating the Equipment
Figure 20 Blender Lifting Lugs 1 on each side
Mounting Configurations
Site Requirements
Machine Mount
Note Larger blenders need to be braced as part of the installation
Mezzanine Mount
Figure 21 Typical Mezzanine Mounted Batch Blender
GRAVIMETRIC BATCH BLENDER MEZZANINE SUPPLIED BY CUSTOMER
Floor Mount Central Blender
Figure 22 Typical Floor Mount Central Blender Layout
3-3 Electrical Connections
3-4 Pneumatic Connections
Figure 23 Customer-Supplied Pneumatic Components
3-5 Initial Set-up
Mechanical Set-up
Stroke Limiters for Metering Gates
Figure 24 Stroke Limiters
Weigh Hopper Installation
Figure 25 Weigh Hopper
Final Connections
Figure 26 Display Startup Screen
Figure 27 Display Main Recipe Screen
Controller Set-up
Blender Controller Menu Structure
Blender Calibration
Figure 28 Display Calibration Menu Screen
Figure 29 Display Calibration Screen
Enter in the Calibration Weight Press here to perform the calibration
Current Loadcell Bits Follow Instructions
Alarm Setup
Figure 30 Display Alarm Flags & Feeder Setup Screen
Feeder Calibration Auger Blenders
Select a Feeder to Configure Change the Alarm Silence Delay
Network Setup
Figure 31 Ethernet Setup Screen
Setting Date and Time
Figure 32 PanelView Configuration Screen
Additional Setup Parameters
3-6 Initial Startup
Quick Start Procedure
Chapter 4 Operation
4-1 Start-up
General Operation
4-2 Operation Procedures
Existing Recipes
Note Press “Push to Start or Stop” button to start blender
Operator Displays
Figure 33 Typical Recipe Entry Operator Screen
Figure 34 Typical Manual Control Operator Screen
Figure 35 Typical Inventory Display Operator Screen
Recipe Entry Formats
Recipe 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” mode
Figure 38 Typical Batch Sizes
Blender
Batch Size lbs
Inventory Shutdown
Auto Start Feature
Mixer and Dump Setup
Mix Timer
Figure 40 Typical Mixer and Dump Setup Operator Screen
Re-Mix Timer
Weigh Hopper Dump Delay Time
Weigh Hopper Dump Time
Alarm Flags
Figure 41 Typical “Out of Material” Alarm Screen
Weigh Hopper Dump Cycle
Mixer Dump Time
Figure 42 Typical “Maximum Hopper Weight” Alarm Screen
MAX HOPPER WEIGHT EXCEEDED check batch size
Figure 43 Typical “Calibration Error” Alarm Screen
Figure 44 Typical “Power Interruption” Alarm Screen
Figure 45 Typical “PLC Battery Low” Alarm Screen
PLC BATTERY LOW
Figure 46 Typical “E-Stop Activated” Alarm Screen
Feeder Clean Out
Figure 47 Typical Manual Control Operator Screen
Recipe Book
Tree Diagram in section 3-5 of this manual
Display Recipe Contents
Figure 48 Typical Recipe Book Operator Screen
Save Running Recipe to the Book
Load a Saved Recipe from the Book
Erase Recipe or Entire Book
Color Changes
4-3 Shut-down
Figure 49 Typical Inventory Shutdown Operator Screen
Chapter 5 Maintenance
5-1 Preventative Maintenance Schedule
Figure 50 Sample Preventative Maintenance Schedule
System model #
5-2 Preventative Maintenance
5-3 Corrective Maintenance
Electrical
Internal Components of the Control Panel
Input Signals to Programmable Controller
Output Signals from Programmable Controller
Note The alarm contact has a maximum load of 3 amps
Chapter 6 Troubleshooting
Problem
6-1 Introduction
Corrective action
Problem
Corrective action
Problem
Corrective action
Problem
warranty will be voided
Corrective action
Service Department
Problem
Corrective action
7-1 Technical Specifications
Equipment Specifications
Figure 52 Equipment Specifications
Chapter 7 Appendix
Annex B Information
7-2 Drawings and Diagrams
Final Assembly
Figure 53 Typical Final Assembly Parts List
Mixer Sub-Assembly
BF1-615.3
Chapter 7 6BAppendix
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Figure 54 Typical Mixer Assembly Parts List
A0770319
Hopper Sub-assembly
Figure 55 Typical Hopper Assembly Parts List
Hopper R.A.M. Regrind Auger Metering Sub-Assembly Optional
Figure 56 Typical R.A.M. Hopper Assembly Parts List
Hopper Additive Feeder Sub-Assembly Optional
Figure 57 Typical Additive Feeder Hopper Assembly Parts List
Weigh Hopper Sub-assembly
Figure 58 Typical Weigh Hopper Assembly Parts List
Slide Gate Sub-assembly
Figure 59 Typical Slidegate Assembly Parts List
Knife Gate Sub-assembly HD Optional
Figure 60 Typical Knife Gate below mixer Assembly Parts List
Knife Gate Sub-assembly RD Optional
Figure 61 Typical Knife Gate floor stand Assembly Parts List
Figure 62 Typical Mitsubishi Controller Main Parts List
Figure 63 Typical Mitsubishi Display Main Parts List
Control Panel Layout
Figure 64 Blender Spare Parts Listing
Spare Parts Kits
7-4 Addendum Service Supervisor Information
Passwords
Programmable Settings
Figure 65 Typical Operator Setup Screen
Figure 66 Typical Engineering Only Setup Screen
Factory Setup Menu
Advanced Weight Options Screen
Metering Test Screen
Figure 68 Typical Advanced Weight Options Screen
Feed Algorithm Options Screen
Figure 69 Typical Feed Algorithm Options Screen
Feed Calibration Options Screen
Feeder Setup
Figure 72 Typical Feeder Setup Screen
Mechanical Options Screen
Figure 71 Typical Mechanical Options Screen
Customer Setup Menu
Figure 74 Typical Ethernet Setup Screen
Units
Figure 73 Typical Units Screen
Figure 75 Typical Alarm Flags & Feeder Setup Screen
Alarm Log
Figure 76 Typical Alarm Log Screen
Alarm Setup
Factory Default Setup Parameters
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VIRGIN
7-5 Mitsubishi Communications Manual
Note ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ/WRITE
GENERAL BLENDER INFO
BLENDER STARTING AND STOPPING
BLENDER 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 MADE
TARGETS VS. ACTUAL WEIGHT INFO
RECIPE BOOK MANIPULATION
Alarm Number Explanation
FIXED DECIMAL EXPLANATION
WRITING RECIPE EXPLANATION
RECORDING THE TARGETS VS. ACTUALS FOR EACH BATCH
UNTIL THE HOPPER FEEDS MATERIAL INTO THE NEW BATCH
Service Department
7-6 Technical Assistance
Parts Department
Sales Department
