Conair GB- WSB User Manual

Gravimetric
Blenders

Instant Access

Parts and Service

[phone]
[phone]

www.conairnet.com

The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: [phone]
Fax: [phone]

GB and WSB models
with 4-component control

UGB006/1103

Installation

Maintenance

Operation

Troubleshooting

It’s a good idea to record the model and serial number(s) of
your equipment and the date you received it in the User
Guide. Our service department uses this information, along
with the manual number, to provide help for the specific
equipment you installed.

Please keep this User Guide and all manuals, engineering
prints and parts lists together for documentation of your
equipment.

Date:

Manual Number: UGB006/1103

Serial number(s):

Model number(s):

Mrev:1/17/2003

DISCLAIMER: The Conair Group, Inc., shall not be liable for errors
contained in this User Guide or for incidental, consequential dam­ages in connection with the furnishing, performance or use of this
information. Conair makes no warranty of any kind with regard to
this information, including, but not limited to the implied warranties
of merchantability and fitness for a particular purpose.

Please record your

equipment’s model and

serial number(s) and

the date you received it

in the spaces provided.

Copyright 2003 All rights reserved

THE CONAIR GROUP, INC.

The Conair Group Inc.

FOUR COMPONENT SOFTWARE

GB and WSB Model Blenders

TABLE of CONTENTS

GETTING STARTED, READ THIS PAGE ................ Page 3

SAFETY HAZARDS ................................. Page 4

DISCLAIMERS .................................... Page 5

PART I - ASSEMBLY

Assembly and Installation Instructions ......... Page 6

Wiring Considerations .......................... Page 10

Check Out Procedure & Diagnostics .............. Page 11

Selecting Correct Model ........................ Page 14

PART II - OPERATION

Load Cell Calibration .......................... Page 15

Rate Calibration ............................... Page 16

Selected Models - Special Instructions ......... Page 17

Instructions for Normal Operation .............. Page 18

Special Features ............................... Page 19

Controls and Outputs ........................... Page 21

Keypad - Summary description ................... Page 26

Automatic mode ........................ Page 27

Manual Mode ........................... Page 31

Program Mode .......................... Page 34

Parameters - Short & Long Explanations ......... Page 44

Default Settings .................. Page 68

Changing / Saving Parameters ...... Page 70

PART III - PRINTER OUTPUTS

Monitoring System Accuracy ..................... Page 71

Special Tests .................................. Page 77

Material Usage Information ..................... Page 78

PART IV - TROUBLESHOOTING / SOFTWARE

What To Do ..................................... Page 79

Increasing Throughput .......................... Page 80

Typical Problems ............................... Page 81

Normal Operating Sequence ...................... Page 83

Verifying Load Cell Function ................... Page 85

Clear RAM, Clear ALL, Full Software Restart .... Page 88

PART V - HARDWARE MAINTENANCE

Hardware Adjustments ........................... Page 89

Mix Problems ................................... Page 91

Recalibration of Load Cells .................... Page 93

Preventive Maintenance ......................... Page 94

Model GT - TOTALIZER Instructions ............. Page 95

Wiring diagram & Supplements ................... Page 97

Exploded Views and Parts List .................. Page 98

Warranty ....................................... Page 99

The Conair Group Inc.

One Conair Drive

Pittsburgh, PA 15202

412-312-6000

FAX # [phone]

Page 2

GETTING STARTED, READ THIS PAGE.

THE NEXT 9 PAGES OF THIS MANUAL WILL GUIDE YOU, STEP BY STEP, TO A
SUCCESSFUL STARTUP.

IT WON'T TAKE LONG; SO.... PLEASE, DON'T SKIP AHEAD.

HERE ARE THE STEPS YOU WILL FOLLOW.

SAFETY HAZARDS: Two hazards exist on this unit: mix blades and
Page 4 slide valves. Read this short sensible page
so no one gets hurt.

ASSEMBLY INSTRUCTIONS: Very little assembly is required. But you
Page 6 might as well get it right the first time.
ALSO: pay attention to the section on wiring.

CHECK OUT PROCEDURE: This is to see if you did it right. It also
Page 11 will tell if anything was damaged in shipping.

LOAD CELL CALIBRATION: We already did this. But shipping or rough
Page 15 handling during assembly sometimes creates load
cell problems. If weight readings are not
correct, you MUST recalibrate the load cells.

RATE CALIBRATION: This is NOT really necessary. But if your
Page 16 system uses non-standard equipment then you
MAY want to do this.

SPECIAL INSTRUCTIONS: A few selected models require special
Page 17 instruction. If your model is listed on this
page, read these instructions.

NORMAL OPERATION: From this point forward, operating your system
Page 18 is a snap. This section tells you just how
simple it is and exactly what to expect under
normal operating conditions.

SPECIAL FEATURES: Your system can do much more then you may
page 19 know. This page reviews briefly some of the
added features that are available to you and
where in this manual you can find them.

+---------------------------------------------------+
¦ ¦
¦ PROCEED TO: SAFETY HAZARDS NEXT PAGE ¦
¦ ¦
+---------------------------------------------------+

Page 3

SAFETY HAZARDS

+-----------------------------------------------------------+
¦ MIX BLADES ¦
¦ ¦
¦ Mix blades are driven with substantial torque. ¦
¦ ¦
¦ NEVER place your hand in the mix chamber ¦
¦ unless power is completely disconnected. ¦
¦ ¦
¦ SERIOUS INJURY may result. ¦
+-----------------------------------------------------------+
+-----------------------------------------------------------+
¦ ADDITIONAL MIX BLADE HAZARD ¦
¦ ¦
¦ Over time, mix blades may become RAZOR SHARP. ¦
¦ ¦
¦ Always be careful when TOUCHING or CLEANING these blades. ¦
¦ Check for sharp edges frequently. ¦
¦ Replace blade if a hazard exists. ¦
+-----------------------------------------------------------+
+-----------------------------------------------------------+
¦ SLIDE VALVES ¦
¦ ¦
¦ Slide valves in hoppers SLAM CLOSED without warning. ¦
¦ They WILL injure your fingers. ¦
¦ ¦
¦ ALWAYS keep fingers clear of slide gate openings. ¦
¦ NEVER use your fingers to clear an obstruction. ¦
¦ NEVER use your fingers to move a sticking slide gate. ¦
+-----------------------------------------------------------+

SAFETY FEATURES

+-----------------------------------------------------------+
¦ SAFETY INTERLOCK SWITCH ¦
¦ ¦
¦ The ACCESS DOOR is equipped with a safety interlock ¦
¦ switch that prevents the mix motor from running and ¦
¦ the slide valves from operating. ¦
¦ ¦
¦ DO NOT defeat this safety switch. ¦
+-----------------------------------------------------------+
+-----------------------------------------------------------+
¦ HOPPER FINGER GUARDS ¦
¦ ¦
¦ Finger guards are fitted into each hopper compartment. ¦
¦ DO NOT reach through these guards. ¦
¦ DO NOT use your fingers to clear an ¦
¦ obstruction below these guards. ¦
¦ ¦
¦ DO NOT remove these guards. ¦
+-----------------------------------------------------------+

+-----------------------------------------------+
¦ PROCEED TO: ASSEMBLY NEXT PAGE ¦
+-----------------------------------------------+

Page 4
DISCLAIMERS

PRODUCTION of FAULTY PRODUCT

Processing conditions and materials vary widely from customer to
customer and from product to product. It is IMPOSSIBLE for us to
anticipate ALL processing conditions and requirements, or to be certain
that our equipment will perform properly in all instances. You, the
customer, must observe and verify the performance level of our
equipment in your plant as part of your overall manufacturing process.
You must verify to your own satisfaction that this level of performance
meets your requirements. We CAN NOT be responsible for losses due to
product that is blended incorrectly, even when due to equipment
malfunction or design incorrect for your requirements; and/or for any
consequential losses due to our equipment not blending to your
requirements.

We will only be responsible to correct, repair, replace, or accept
return for full refund if our equipment fails to perform as designed,
or we have inadvertently misrepresented our equipment for your
application.

ACCURACY of THIS MANUAL

We make every effort to keep this manual as correct and current as
possible. However, technology and product changes occur more rapidly
then the reprinting of this manual. Generally, modifications made to
the design of the blender or to the operation of the software are not
reflected in the manual for 3 to 6 months. We always reserve the right
to make these changes without notice, and we do not guarantee the
manual to be entirely accurate. If you question any information in
this manual, or find errors, please let us know so that we may make the
required corrections. We will gladly provide you with updated manuals.

Page 5
+--------------------------------------------------------------------+
¦ PART I - ASSEMBLY ¦
+--------------------------------------------------------------------+

ASSEMBLY and INSTALLATION INSTRUCTIONS

CAUTION: LOAD CELLS ARE EASILY DAMAGED.
If the FRAME is dropped from TWO FEET, the load cells WILL be DAMAGED.
PLEASE, BE CAREFUL.

The following items have been shipped to you:

1. FRAME, fully assembled: (bolted to pallet)

2. CONTROLLER: the controller and the instruction manual.

3. FEEDERS: optional COLOR or ADDITIVE feeders as ordered.

4. FLOW CONTROL ASSEMBLY: optional

5. FLOOR STAND or VACUUM TAKEOFF ASSEMBLY: optional

RED INSTRUCTION STICKERS will assist you during assembly.

LIFT HANGERS are available to allow lifting of the blender with a strap
or chain. Call us if you require them.

1A. If your unit is to be MACHINE mounted:
For GB/WSB 100, 200, and 400 series models:
Two ways to do this are suggested ON THE NEXT PAGE.

The LEFT diagram shows the FRAME and SLIDE GATE both drilled
with the proper bolt pattern for your machine and THROUGH­ BOLTED to your press.

The RIGHT diagram shows only the 10 x 10 steel slide-gate plate
drilled for your bolt pattern and bolted to your press. The
FRAME is then bolted to it using the 8 x 8 inch bolt pattern
holes and bolts provided. With this method, bolt head
clearance holes are required in the poly-pro slide gate plate.
This mounting works well on smaller machines.

For GB/WSB 900 and 1800 series models:
An additional machine mount adaptor plate may be required. If
you have ANY DOUBT about the STABILITY of the unit when bolted
directly to your machine throat, please call us for advice.

NOTE: When choosing proper orientation, be sure you have access to
the controller and weigh chamber, clearance for hinged doors,
and access to removable feeder hoppers.

1B. If your unit is STAND mounted:
A stand is provided and your unit will bolt directly to it.
An assembly DIAGRAM is provided if stand assembly is required.

An air operated FLOW CONTROL ASSEMBLY is provided for dispensing
into a container. The purpose of this unit is to allow time for
mixing to occur after each dispense. This flow valve keeps the
mix chamber full to just below the sensor. This assembly bolts
directly to the bottom of the Blender frame.

Page 8

2. Slide the WEIGH BIN into position. It rests high in the frame and
is inserted from the side that has the hinged access window.
Install with the air cylinder toward you. If bin is already in
place, remove any shipping materials, tape or string.

3. Hang the Color and Additive Feeders:

a. Lift side latches and fully extend slide assembly. Remove the
hopper. Leave slide extended.

b. Raising the rear of the slide assembly, insert one corner of
hanger cross bar behind frame corner post.

c. Rotate assembly into place so both ends of cross bar are behind
corner posts.

d. Lower into place, bottom edge resting on frame and cross bar
properly positioned behind corner posts.

e. Re-install hopper. Slide motor forward until latches engage.

4. Place the controller on the support tray and plug in all cords:

a. Air solenoids into the multi-pin plug.
b. Additive and color feeders into panel front receptacles.
c. Mixer motor into right side of controller.
d. Sensor cord plug into right side of controller.
e. Load Cell plug into port on left side of controller.

5. Plug the CONTROLLER into the receptacle box located under the
controller tray on GBM, 100, 200, and 400 series models; and in the
mix motor relay box on 900 and 1800 series models.

IMPORTANT: Do NOT plug the controller into a separate power
source. The controller ground path MUST be the same as
the blender frame ground path. If your system has the
controller located in a remote location, MAKE CERTAIN
that the power to the controller comes from the
receptacle mounted on the Blender frame.

6. Plug the power cord coming from this box into a 110 volt power
source (230 volt outside U.S.). This cord MUST provide the ONLY
power source for the entire system, including the controller.
See WIRING CONSIDERATIONS, next page. 1800 series blenders require
a separate power source for the mix motor.

7. Connect air pressure to the unit. About 80 psi (5.5 bar) is
recommended. Lubricated air is NOT recommended.

NOTE: Micro Blenders should be set to 40 psi (2.7 bar).
The Vertical Valves used in removable hoppers on Micro
Blenders, and 100 and 200 series blenders, are more accurate
at the lower 40 psi pressure setting.

8. Remove all protective paper from the plastic windows.

Page 9

WIRING CONSIDERATIONS

The wiring of your blender is very important to its proper operation.
Electronics are very susceptible to voltage spikes and static charges,
both of which are very common in plastics factories.

To MINIMIZE these things, consider the following.

1. The power supply should be solid; a strong supply, not limited by a
"just adequate" control transformer. A source of voltage that
comes from a large transformer that supplies a large portion of the
plant is better then a small power supply transformer that is
intended to supply only this device. Power supplies, even though
they may be "isolation" transformers, will still pass all voltage
spikes right through. Their small size limits their ability to
dampen RF (Radio Frequency) noise that is often induced into the
system from outside sources. This proves worse then connection to
larger central transformers.

2. Avoid running the power supply line along side any heavy power
lines. An unshielded power supply in a raceway along side other
heavy power lines will pick up induced RF noise and transfer it
into the GB/WSB steel enclosure causing computer trouble.

3. Long extension cords should be avoided. They also reduce the
ability to provide a dampening effect on spikes and static. The
further the equipment is from a substantial power source, the more
susceptible it is to spikes.

4. The CONTROLLER and the GB/WSB frame MUST share the same GROUND PATH.
This is why you MUST plug the controller into the OUTLET that is
provided ON THE FRAME of the blender.

5. REMOTE SYSTEMS. If you have your controller mounted in a remote
location, you will have a number of power and signal cords running
between the frame and the controller. BE SURE that the LOW VOLTAGE
lines are NOT BUNDLED to the HIGH VOLTAGE lines and keep them away
from other nearby electrical lines.

LOW VOLTAGE lines are: Load Cell cable, Level Sensor cord, Air
Solenoid cable, and Printer and Computer cables.
HIGH VOLTAGE lines are: Mixer motor cable, feeder motors, and MAIN
POWER line.
Keep these sets of cables SEPARATED.

6. VACUUM LOADER CONVEYING LINES. Keep them away from all electrical
lines, particularly the Load Cell lines. Conveying plastic
produces extreme static sources. A power supply line, even in
conduit, that runs next to a vacuum line, can introduce extreme
static pulses into the processor. Keep conveying lines SEPARATED
from electrical supply lines.

7. We use many internal tooth "STAR" washers in assembly to ensure a
good ground path between painted parts. Do not remove them.

+----------------------------------------------------+
¦ PROCEED TO: CHECK OUT PROCEDURE NEXT PAGE ¦
+----------------------------------------------------+

Page 10

CHECK OUT PROCEDURE

As you go through this procedure, if WHAT SHOULD HAPPEN, doesn't
happen, see the next section, DIAGNOSTICS, for what to check.

NOTE: 100 and 200 series models (3K load cells), display all weight
readings in 1/10 grams ( x.x). 400, 900, and 1800 series
models (10K load cells) display in FULL grams, no decimal.

On this page we show all weight readings WITH a decimal point.

Start with NO MATERIAL in any hoppers.
Be sure an AIR SUPPLY is connected.
Place ALL switches DOWN; POWER (on front); STOP and PAUSE (on left).

PROCEDURE: WHAT SHOULD HAPPEN: .

PLUG IN CONTROLLER. Nothing should happen.
Air pressure should be holding ALL valves CLOSED.
This means all air cylinders are extended. If any
slide gate or flap is open, air lines are
reversed.

TURN POWER ON. Display should show ( FOUR ), software type,
followed by version date (V=50920A),
followed by the check sum number (CKS xxxx),
followed by (ROM OK ),
followed by (RAM = 8K),
followed by (MODEL220) or MB, 140, 131, 122, 240,
420, 440, 940, 1840. (NOTE: The MODEL
number must match your unit, except for
the zero. If not see below.)
followed by ( 0.0),
followed by the actual weight of material in the
bin. This number should be close to 0, plus or
minus several grams ( 20.0) to (- 20.0).

AT THIS POINT: Be sure the display is in tenths of grams,
or full grams depending on your model.

If the weight display is NOT correct, or
the MODEL number is not correct;
see SELECTING CORRECT MODEL, next section.

TOUCH WEIGH BIN VERY LIGHTLY.
Display should update the weight every second
reflecting the light pressure that you are
exerting on the bin.

PRESS "*" KEY Display will say (PASSWORD)

PRESS "22222" (2 key five times) (entering the Program mode)
2's will be displayed as you enter them.
Display will show (P x.x) when done.

PRESS "OPER" KEY Display will say (OPERATE )

Page 11

PRESS "REG" KEY Regrind air solenoid will operate.
LED # 1 will light.
The Regrind dump valve will open.
Press "REG" repeatedly to observe operation.

PRESS "NAT" KEY Natural air solenoid will operate.
LED # 2 will light.
The Natural dump valve will open.
Press "NAT" repeatedly to observe operation.

PRESS "COL" KEY Internal relay will close powering Color outlet.
Color feeder will run.
LED # 3 will light.
Press "COL" repeatedly to observe operation.

PRESS "ADD" KEY Relay will close powering Additive outlet.
Additive feeder will run.
LED # 4 will light.
Press "ADD" repeatedly to observe operation.

PRESS "DUMP" KEY The dump air solenoid will operate.
LED # 5 will light.
The weigh bin dump valve will open.
Press "DUMP" repeatedly to observe operation.

PRESS "ALARM" KEY The Strobe Light and Beeper will operate.
LED # 6 will light.

PRESS "MIX" KEY The Mixer Motor will run.
LED # 7 will light.
(Mix blade turns counter clockwise when observed
through window.)
(Mixer switch must be down; timed position.)

PRESS "HOLD" KEY The Flow Control Valve will operate.
(This is an optional device).
LED # 8 will light.

PRESS "EXIT" KEY Press two times to return to normal mode.
Verify normal mode by observing that there is NO
letter P in the display ( x.x).

+-----------------------------------------------------------+
¦ If you have made it this far, congratulations. ¦
¦ You have done well. ¦
¦ The load cells and controller are functioning properly. ¦
+-----------------------------------------------------------+

+--------------------------------------------------------+
¦ ¦
¦ PROCEED TO: LOAD CELL CALIBRATION Skip 2 Pages ¦
¦ ¦
+--------------------------------------------------------+

Page 12

DIAGNOSTICS - for the CHECK OUT PROCEDURE

If display fails to come on at all:
check for power at outlet.
Check the 1/2 amp fuse on panel front.

If first display says ( TWELVE ), this is NOT the correct manual for
this software. Obtain a TWELVE software manual.

Possible model numbers are: 140, 220, 240, 420, 440, 940, 1840.
If model number is not correct for you unit:
see the next page, SELECTING CORRECT MODEL.

If display stays at ( 0.0):
check for damage to load cells or load cell wires.
Load cell distorted upward may produce a display of ( 0.0).

If unit displays randomly drifting numbers:
check to see load cells are plugged in.

If display shows about (- 1250.0) or ( -4500) for 900 series:
check that the weigh bin is in place resting on the load
cells. This number is about the weight of the weigh bin.

If display is steady but not near zero:
Recalibration of load cells will most likely fix this. This
is covered in next section.

If there is no response from the display when the bin is touched:
check that load cell plug screws are secure.

If response is not sensitive or does not return to its start point:
check for interference around weigh bin.

If pressing * does not display (PASSWORD):
you are not in the normal power-up mode or the keypad
doesn't work. Normal mode is indicated by the ABSENCE of
the letter M or P at the left of the display.

If display says INVALID after entering the password number:
you pressed the wrong keys or the password number has been
changed and it is no longer 22222. Call us for help.

If an air solenoid does not operate:
check the 1/2 amp fuse.
check solenoid cable connected properly and fully seated.
check mix chamber door closed, safety interlock engaged.

If a slide or dump valve does not open:
check that the air supply is connected.
check for proper air line connections to cylinder.

If color or additive auger motor does not run:
check the 3 amp fuse.
check that the motor is plugged into proper outlet.
check for faulty motor by plugging it into a known source of
110 volt A.C. power.

Page 13

We program every controller to match the model it is shipped with.
If your controller DOES NOT display the correct model (first two digits
only) on power up, follow these instructions.

There are SEVEN basic models of Weigh Scale Blenders. The MODEL number
your unit is set for (first two digits only) is displayed during the
start up sequence every time power is turned on. Disregard the last
digit of your model number when selecting from this list.

The possible models are:
MODEL BATCH WEIGHT WEIGH BIN # DISPENSE LOAD CELL
(GRAMS) DIMENSIONS VALVES RATING

GBM Microblender 400 5 x 5 x 5 high 4 1 @ 3 K
140,131,122,14R 1000 10 x 6 x 6 high 4 1 @ 3 K
220 2000 10 x 10 x 7 high 2 2 @ 3 K
240,24R 2000 10 x 10 x 7 high 4 2 @ 3 K
420,44R 4000 10 x 10 x 10 high 2 2 @ 10 K
440 4000 10 x 10 x 10 high 4 2 @ 10 K
940 9000 16 x 16 x 12 high 4 2 @ 10 K
1840 18000 16 x 16 x 17 high 4 2 @ 20 K

400, 1000 and 2000 gram systems with 3 kg. load cells; weights are
displayed in tenths of grams ( xxxx.x).

4000, 9000, and 18000 gram systems with 10 or 20 kg. load cells;
weights are displayed in full grams ( xxxxx).

If your unit is NOT set correctly to match the hardware you have, you
must change it. To do so:

Turn power on. From the NORMAL mode:

+-------------------------------------------------------+
¦ Press: * Display will say: (PASSWORD) ¦
¦ ¦
¦ Press: 97531 Display will say: (MODEL240) ¦
¦ or whatever model it is set for. ¦
¦ ¦
¦ Press: * To walk through all seven models. ¦
¦ When the model you want is displayed,¦
¦ then: ¦
¦ ¦
¦ Press: EXIT Wait a few seconds. ¦
¦ Unit will reset and restart ¦
¦ as the system you have selected. ¦
+-------------------------------------------------------+

When switching models, all parameter table information is lost and the
new "default" information for this model is loaded from ROM.

Page 14

+--------------------------------------------------------------------+
¦ PART II - OPERATION ¦
+--------------------------------------------------------------------+

LOAD CELL CALIBRATION

NOTE: Display examples shown here are in tenths of grams as displayed
On 100 and 200 series models. 400, 900 and 1800 series models
display full grams, no decimal.

If your load cells are displaying a weight close to ( 0.0), plus or
minus 5 grams, you may skip this section and go directly to
RATE CALIBRATION (next page).

If your unit DOES NOT display a weight of ( 0.0) grams, plus or
minus 5 grams, you should recalibrate them, that is reset ZERO weight,
at this time.

To do so:

BE SURE the weigh bin is EMPTY.
BE SURE the load cell plug is plugged into the side of the controller.
BE SURE the weigh bin is resting on the load cells freely.
BE SURE the air line to the dump valve is connected as it would be
during normal operation. (A disconnected air line adds weight.)
BE SURE The load cells and bin are not jammed in any way. To test for
this see that a light touch on the bin causes the display to
change. When the pressure is removed the display must return
to exactly where it was, plus or minus 0.1 gram.

If this does not happen, something is touching something and
the bin is not entirely free to move. Check EVERYTHING around
the bin.

LOAD CELL CALIBRATION:
The sequence of keystrokes is as follows:
+------------------------------------------------------+
¦ Press: * Display will say: (PASSWORD) ¦
¦ Press: 22222 Display will say: (P x.x) ¦
¦ Press: *99 Display will say: (CAL OFF) ¦
¦ Press: * Display will say: (CAL ON ) ¦
¦ Press: EXIT Display will say: (P x.x) ¦
¦ Press: ZERO WT Display will say: (--WAIT--) ¦
¦ followed by: (P 0.0) ¦
+------------------------------------------------------+

The ZERO point of the load cells is now set properly. FULL weight
calibration may also be done at this time, however, it probably is NOT
NECESSARY. When load cell readings shift due to rough handling, the
entire range of readings from ZERO to FULL shift together. ZERO weight
calibration resets the full range of the cells and, therefore, corrects
FULL weight readings as well. For information on FULL weight
calibration, see RECALIBRATION OF LOAD CELLS section.

+-----------------------------------------------------+
¦ PROCEED TO: RATE CALIBRATION NEXT PAGE ¦
+-----------------------------------------------------+

Page 15

RATE CALIBRATION

RATE CALIBRATION is probably not necessary. The software initially
expects STANDARD hardware. However, if you are using an auger feeder
on a model with four dispense valves, or a 1/2 inch auger instead of a
1" auger, the software will take 10 or 20 cycles to adjust to correct
operation. This slows down the process for a short time, but does not
effect accuracy.

If your hardware is STANDARD, or
you prefer letting the system SELF ADJUST,
you may:
+---------------------------------------------------+
¦ ¦
¦ PROCEED TO: NORMAL OPERATION NEXT PAGE ¦
¦ ¦
+---------------------------------------------------+

To perform a RATE CALIBRATION:

Have all HOPPERS LOADED with enough material to run for several cycles
without running out.

Have the "OFF AT END OF CYCLE" and "PAUSE" switches DOWN.

Press: * Display will say: (PASSWORD)
Press: 22222 Display will say: (P x)

If your system has auger feeders, operate them briefly to ensure they
are fully primed. To do so:

Press: OPER Display will say: (OPERATE )
Press: COL Run until auger is dispensing.
Press: ADD Run until auger is dispensing.
Press: DUMP This will empty the weigh bin.

Now you can CALIBRATE EACH material.
To do so:

Press: CAL Display will say: (CALIBRATE)
Press: REG REGRIND will calibrate itself.

For each material, press CAL followed by the proper component key.
Each time a dispense will occur, followed by weighing, followed by
a dump to empty the weigh bin.

Press: EXIT when all calibrations are done.

YOU ARE NOW READY FOR ACCURATE PRODUCTION BLENDING.

+---------------------------------------------------+
¦ ¦
¦ PROCEED TO: SPECIAL INSTRUCTIONS NEXT PAGE ¦
¦ ¦
+---------------------------------------------------+

Page 16

SELECTED MODELS - SPECIAL INSTRUCTIONS

This section relates SPECIAL information about a few selected models.

MICRO PULSE

Micro Pulse valves are available on models:
GB/WSB MB (MICRO Blender) with optional MICRO PULSE valves.
GB/WSB 122 with optional MICRO PULSE valves.
GB/WSB 131 with optional MICRO PULSE valves.
GB/WSB 140 with optional MICRO PULSE valves.
GB/WSB 240R with optional MICRO PULSE valves.
GB/WSB 440R with optional MICRO PULSE valves.

These models may use our "MICRO PULSE" metering system for Color and
Additive components.

PULSED OUTPUT parameters control the on/off timing, or pulsing, of the
valves. The controlling parameters are the "_PO" component parameters.

When set to 00000, normal slide gate operation occurs.
When set to a value, such as 00101, power will pulse ON then OFF, at
1/10 second time intervals each way. This ON/OFF cycling will repeat
for the entire dispense time.

When using a MICRO PULSE valve, you must set the related _PO parameter
to 00101.

If overall blender throughput is too low, you may increase the metering
rate of each Micro Pulse device by adjusting the cylinder air flow
control valves for higher flow rate. This causes more rapid movement
of the cylinder, ejecting more pellets per pulse. The drawback is
noisy operation.

We recommend air flow be adjusted for quiet operation, but assuring
full valve movement per on/off cycle. We have already done this. No
further adjustment should be necessary.

The approximate correct adjustments are:
At nose of cylinder, 1.5 full turns out from full closed.
At rear of cylinder, 2.5 full turns out from full closed.
MICRO BLENDER slant valves, adjust by sound.

On fixed hoppers with horizontal micro pulse valves, CLEAN OUT of the
hopper can be accomplished by opening the "clean out" port provided
under the valve. Turn to one side to allow material to drain.

MICRO PULSE - ACCURACY
All MICRO PULSE valves are more accurate if the associated PT parameter
is set to 00090. Read PT parameter in the PARAMETER section.

+---------------------------------------------------+
¦ ¦
¦ PROCEED TO: NORMAL OPERATION NEXT PAGE ¦
¦ ¦
+---------------------------------------------------+

Page 17

INSTRUCTIONS FOR NORMAL OPERATION

OPERATION: ....very simple.

1. Fill HOPPERS: REGRIND, NATURAL, COLOR, ADDITIVE:
in hoppers as labeled.
If auger feeders are used:
COLOR in RIGHT side feeder,
ADDITIVE in LEFT side feeder.

2. Set THUMBWHEEL switches for percentages desired.
REGRIND, enter as a percent of the entire mix. (xx percent)
COLOR, as a percent of the NATURAL. (xx.x percent)
ADDITIVE, as a percent of the NATURAL. (xx.x percent)

3. On Controller, turn POWER ON, set STOP, and PAUSE switches UP.
Switch MIXER motor DOWN to run for a timed period each cycle.

Unit will now operate automatically to maintain a level of material
high enough to cover the sensor.

Use the STOP or PAUSE switches to stop the dispensing of material.
Turn POWER off only on final shutdown. Battery-backed RAM ensures
all information is retained even with power turned off.

The KEYPAD is only for: 1. MANUAL TESTING.

2. ALTERATION of INTERNAL PARAMETERS

----------------------------------------------------------------------

AFTER SEVERAL DAYS OF PROPER OPERATION:

Save all parameter information to the EEPROM for future retrieval
should software problems develop later.

To SAVE all parameter information to the EEPROM:

+---------------------------------------------------+
¦ Press: * Display will say: (PASSWORD) ¦
¦ Press: 22222 Display will say: (P x.x) ¦
¦ Press: * Display will say: (INSTR --) ¦
¦ Press: 23 Display will say: (SAVING ) ¦
¦ Wait: when done, Display will say: (P x.x) ¦
¦ Press: EXIT Display will say: ( x.x) ¦
+---------------------------------------------------+

IF PROBLEMS DEVELOP:
RETRIEVE this correct copy of the parameters from the EEPROM. This
clears corrupted data from RAM and corrects most software problems.

+----------------------------------------+
¦ Switch: POWER OFF. ¦
¦ Hold: the "CE" key down. ¦
¦ Switch: POWER ON. ¦
¦ Release: the "CE" key. ¦
¦ Display will say ( CLEAR ) ¦
¦ If you do not see ( CLEAR ) ¦
¦ on the display, do it again. ¦
+----------------------------------------+

Page 18

NORMAL OPERATING SEQUENCE - EACH CYCLE

As the sensor is uncovered, the cycle begins. The target weight of a
complete depends on model; 400, 1000, 2000, 4000, 9000, or 18000 grams.

REGRIND, if requested, will dispense first. After the Regrind dispense
the space remaining in the weigh bin is calculated.

NATURAL will dispense second. This dispense is calculated to fill the
bin leaving just enough space for the Color and Additive dispenses.
After the Natural dispense is complete the exact weight of this
dispense is calculated and, based on this actual dispense weight, the
Color and Additive dispenses are now calculated.

COLOR and ADDITIVE are now dispensed one at a time as requested. These
dispenses are a percentage of the Natural component only.

If the Natural, Color, or Additive components fail to reach the
requested weight, the process does NOT CONTINUE. The ALARM Strobe
light flashes and the system holds until the problem is remedied.

As each component is being dispensed and weighed, the corresponding
letter (R, N, C, or A) is displayed. The total updated bin weight is
displayed about 3 seconds AFTER each dispense.

Each dispense weight is checked and recorded. Rate recalibration takes
place every cycle to ensure continuous process accuracy.

The total batch is dropped into the mixing chamber and blended before
entering the throat of the process machine.

SPECIAL FEATURES

To use one of these SPECIAL FEATURES, read about it first, then follow
the directions on next page to make the proper changes.

To store RECIPES using the RECIPE storage feature, read:
KEYPAD, RECIPE key, and set 3rd digit in the FLG parameter to 1.

To blend a preset BATCH amount of material and then stop, read:
KEYPAD, BATCH key, and set 5th digit in the FLG parameter to 1.

To increase throughput, using the FAST key, read:
KEYPAD, FAST key, and set 4th digit in the FLG parameter to 1.

To TAG all material usage data with Work Order or Employee numbers for
better tracking of material used, read:
KEYPAD, TAG key, and set 2nd digit in the FLG parameter to 1.

BATCH, RECIPE, FAST, and TAG keys REQUIRE that you read:
PARAMETERS, FLG parameter.

To change the MIXER RUN TIME, read:
PARAMETERS, MIX Parameter.

Page 19

To run a LOWER PERCENTAGE then 00.1 percent, read:
PARAMETERS, _XT parameter.

To place UPPER LIMITS on the thumbwheel settings, read:
PARAMETERS, _SE Parameter.

To LOCK OUT others from changing settings, read:
KEYPAD, STAR FUNCTIONS, (*78) - Changing the Password.

To blend TWO NATURAL materials instead of Natural and Regrind, read:
KEYPAD, STAR FUNCTIONS, (*69) - the TWO NATURALS flag.

To TRACK MATERIAL usage, read:
KEYPAD, VIEW DATA, and PARAMETERS, PRT Parameter.

To VERIFY ACCURACY of the entire system, read:
PRINTER OUTPUT and TROUBLESHOOTING sections.

READ the rest of the manual at your leisure to learn more about how
your WEIGH SCALE BLENDER works and what else it can do.

KEYSTROKE SEQUENCE for these or other SPECIAL FEATURES

With STOP END OF CYCLE switch DOWN,
Turn POWER ON. Wait 5 seconds, until display says ( x.x)
Press: * Display will say (PASSWORD)
Press: 22222 Display will say (P x.x)
This is the PROGRAM MODE

To alter a PARAMETER; press: PARA key
Press repeatedly until the parameter you want is displayed.
If you pass it, use the * key to back up.
With the proper one displayed, enter the NEW parameter number.
Enter 5 digits; use leading zeros if necessary.
For correct entries, follow specific directions given in the
PARAMETER section.

Press: EXIT when correct parameter has been entered.

To make a (*XX) entry:
Be in the PROGRAM mode, same as above.
Display will say (P x.x)
Press: * Display will say (INSTR --)
Enter the 2 digit code.
For correct entries, follow specific directions given in the
KEYPAD section, STAR FUNCTIONS.

Press: EXIT when correct information has been entered.

When finished, press EXIT again to exit the PROGRAM MODE.

Page 20

CONTROLS and OUTPUTS

1. POWER ON switch.

Controls all power to the controller and all outputs. When power is
switched off, battery backed-up RAM preserves all internal totals and
parameters. All other functions are reset for normal start-up when
power is restored.

2. STOP END OF CYCLE / CONTINUE switch

This is the PREFERRED STOP switch. This switch is wired in series with
the level sensor. Turning it off breaks the signal to the computer the
same as covering the level sensor with material. This stops the
process at the end of a full cycle.

3. IMMEDIATE PAUSE / CONTINUE switch

Causes a computer-controlled immediate pause in the cycle. Dispenses
will stop in mid dispense if necessary. When switched back to
CONTINUE, the process continues without any error in amounts dispensed.

4. REGRIND thumbwheel switch (00 to 99)

This setting represents the PERCENT of the ENTIRE MIX that is to be
REGRIND.

A lower limit of 5% (05) has been entered into the software. This
limit may be altered using the keypad (see parameters, RLO).

A setting of "99" causes the system to run 100 percent regrind. With
this setting, no attempt is made to meter natural, color, or additive
unless the regrind dispense fills less than 1/2 of the weigh bin.

5. COLOR thumbwheel switch (00.0 to 99.9)

This setting represents the PERCENT of the NATURAL PORTION that is to
be COLOR. For example, if your COLOR to NATURAL mix ratio is 1:25 then
"04.0" is the proper setting. (1 pound of color to 25 pounds of
natural is 1/25 = 4%)

6. ADDITIVE thumbwheel switch (00.0 to 99.9)

This setting represents the PERCENT of the NATURAL PORTION that is to
be ADDITIVE. For example, if your ADDITIVE to NATURAL mix ratio is
1:100 then "01.0" is the proper setting (1/100 = 1%).

Page 21

7. ALL AIR SOLENOID outputs

This is a single 17 pin Amphanol plug located on the front of the
control panel. This provides 24 volt power for the NATURAL, REGRIND,
WEIGH BIN DUMP, and FLOW CONTROL (optional) air solenoids. On Models
140, 240, 440, 940, and 1840 (FOUR valve units), COLOR and ADDITIVE
dispense valve solenoids are also powered. These power sources are
transistor driven and are protected by the 1/2 amp panel fuse. See the
wiring diagram section for the correct wiring to each pin.

8. COLOR and ADDITIVE power outlets (certain models only)

Each outlet puts out 120 volts (220 volts outside U.S.A.) through
internal plug-in solid state relays rated at 5 amps and fused at 3
amps. These relay outputs are designed to drive motors or other
devices requiring power up to 3 amps each.

The COLOR outlet is driven based on the COLOR setting. The ADDITIVE
outlet follows the ADDITIVE setting. COLOR dispense occurs first but
has no effect on the ADDITIVE dispense. The amount of each dispense is
calculated based on the NATURAL dispense that precedes them.

9. EIGHT CHARACTER DISPLAY

Displays the accumulated total bin weight, in grams, 2 seconds after
each dispense. The display flashes when an inadequate dispense has
occurred and the dispense is going to be retried. Other information
displayed here includes material usage totals, internal parameters,
current thumbwheel settings or keypay entered settings, and various
information prompts to assist the operator.

####.# Numbers displayed are the total weight of material, in grams,
in the bin at any time. The weight in the bin is updated 2
seconds after an each dispense is completed. During the
dispense the displayed weight does not change.
P in the left most position indicates unit is in PROGRAM mode.
M indicates unit is in MANUAL mode.
R, N, C, or A indicates the component being dispensed.
INVALID indicates:

1. you pressed an incorrect key,

2. you pressed a key for a function that is not active, or

3. you are not in the right mode for this key to operate.
PASSWORD is displayed when you press the "*" key from the normal mode.
Enter "11111" for MANUAL mode or "22222" for PROGRAM mode or
enter your own password number if you have established one.
SETTING, OPERATE, TIMED, and CALIBRATE are displayed when the
respective keys are pressed from the manual or program modes.
These displays are followed by pressing a device key; REG,
NAT, COL, ADD, DUMP, ALARM, MIX, or HOLD.
FLASHING means that retries are occurring because the first dispense
was not enough. Other error conditions also cause flashing.
ROM OK or ROM BAD indicates condition of ROM chip.
See KEYPAD, *25 for explanation.

Page 22

10. LED LIGHTS

The LED lights in two vertical columns of eight located above the 8
character display indicate the following:

LEFT COLUMN:

1. REG Regrind dump solenoid operating.

2. NAT Natural dump solenoid operating.

3. COL Color drive relay operating.

4. ADD Additive drive relay operating.

5. DMP Dump valve solenoid operating.

6. ALM Alarm output operating.

7. MIX Mixer motor drive relay operating.

8. HLD Mixer flow valve is open (Optional).

RIGHT COLUMN:
ALARMS

1. Alarm is on because Regrind ran out.

2. Alarm is on because Natural ran out.

3. Alarm is on because Color ran out.

4. Alarm is on because Additive ran out.

5. Alarm is on because Weigh bin is not within limits.

6. C Color thumbwheel switches are locked out and the setting
being used does not match the thumbwheel setting.

7. A Additive thumbwheel switches are locked out and the
setting being used does not match the thumbwheel setting.

8. R Regrind thumbwheel switches are locked out and the setting
being used does not match the thumbwheel setting.

11. STROBE LIGHT AND BEEPER ALARMS

The Strobe light flashes and the Beeper sounds when NATURAL, COLOR, or
ADDITIVE fail to meter properly. Alarms begin after a preset number of
retries have occurred. The number of retries before Alarm is
determined by settings in the parameter table (see parameters _AL).
Regrind can also be alarmed.

12. ALARM SILENCE

This button stops the STROBE and BEEPER ALARMS. The continuation of
the cycle to its proper completion will also stop the alarm.
If the BATCH mode is in operation, this button starts the next batch.

13. LEVEL SENSOR input

The high level sensor in the mixing chamber plugs into this outlet and
signals the controller to start a dispense cycle when it is uncovered.
The sensor must be uncovered for at least 2 seconds before a cycle will
start. (see DLY 00488) parameter). Once a dispense cycle is started,
covering the sensor does not stop it. Operation continues until the
cycle is complete.

Page 23

14. MIXER MOTOR OUTLET

This outlet is energized continuously when the MIXER SWITCH is ON (up).
In the TIMED position, it stays energized for a time period following
the dump of the weigh bin. You may adjust this time in the parameter
table (MIX 03010). This time should be just long enough to provide
adequate mixing. Mixing for a longer period may contribute to a static
problem. Also, excessive mixing sometimes causes separation of pellets
of different size and weight.

15. MIXER MOTOR ON/OFF/TIMED SWITCH

The ON/OFF switch is provided as a safety so you may switch the mixer
off when you wish to clean out the mix chamber. In the UP position
(ON), the mixer runs continuously. In the middle position (OFF) the
mixer is off. In the down position (TIMED), the mixer will run for a
timed period following the dump of the weigh bin.

16. MIXER MOTOR FUSE

This fuse is rated at 3 amps and protects the mixer motor circuit
separately from all other fuses. On 100, 200, and 400 series models,
this fuse protects the mix motor directly. On 900 and 1800 series
models, this circuit operates a 25 amp solid state relay in a separate
box. These larger mix motors are protected by a "motor starter" switch
with a "heater", which must be on for the motor to operate.

17. LOAD CELL input port

The system's two load cells are joined by a common connector that is
plugged into this port.

18. PRINTER output

This is a parallel printer port. A printer plugged in here allows four
types of information to be ported directly to a printer giving the
benefit of a permanent printed record. They are:

1. The totals of the material usage data.
(press VIEW and "*" keys to print once; or use the PRT parameter
to AUTOMATICALLY and periodically print these totals)

2. A listing of the internal parameter table.
(press *77 in the PROGRAM mode.)

3. A printout of information after each cycle including actual
dispensed weights and percentages for every cycle.
(press *54 in the PROGRAM mode, use "*" to set printer flag ON.)

4. A printout of information after the TIME or CALIBRATE routines.

Any common parallel printer that you would use with a small PC computer
may be used. Connect using a standard parallel printer connecting
cable, (34 pin parallel centronix connector to a DB25 IBM compatible
connector), available from us or at any computer store. There is a
detailed explanation of this printout in the PRINTED OUTPUTS section of
this manual.

Page 24

19. COMPUTER input / output

If you choose to gather material usage data automatically and
continuously by computer, this connector allows for connection to an
IBM PC type computer operating under MS-DOS or WINDOWS.

The COMPUTER port is a DB9 (9 pin) male port. You will need a
specially wired cable from us to connect to the serial output on your
standard PC computer. You will also need software from us for
communicating with your Weigh Scale Blender. Your computer operating
system must be MS-DOS or WINDOWS. This software allows downloading
settings and retrieval of information and will produce extensive
reports for those customers who wish to take advantage of this feature.

One or many Weigh Scale Blenders can be connected to one computer.
Customers that wish to do their own programming may interact with the
Weigh Scale Blenders by way of a single program that we provide. This
program, when executed, gathers all current totals from all controllers
and moves them into an ASCII text file for access by other software.

For multiple Weigh Scale Blender systems, or communication over long
distances, an additional piece of hardware is required. All GB/WSB
controllers are fully programmed to communicate with your computer now
or at a later date.

20. PANEL FUSE for duplex receptacle - 3 amp

Fuses the common power wire of the duplex receptacle (the color and
additive outputs). Since these outlets are only turned on one at a
time, each is protected to the full 3 amp rating of the fuse.

21. PANEL FUSE for processor - 1/2 amp

Fuses power to the circuit board power supply which includes all
solenoid outputs and solid state relay outputs.

22. INTERNAL FUSES

An in-line fuse is provided internally to protect the main 120 volt
power cord supply (10) amps. If this fuses blow, an internal short
circuit is indicated and we don't recommend that you try to fix it.
Remember, this unit carries a five year warranty; just send it back.

The MIX MOTOR timed power source and the AUGER FEEDER OUTLETS are
driven by internal solid state plug-in relays. These relays are
located on the circuit board mounted on the inside back surface of the
controller enclosure. A small 5 amp glass fuse is located to the right
of each relay. A spare fuse is also located on the board if
replacement is necessary.

23. KEYPAD
The KEYPAD is explained extensively in the next section, next page.

Page 25

Detailed explanations are given on the pages that follow.

AUTOMATIC OPERATION MODE: (normal operation on power up)
These keys are operational in this mode.

VIEW: View Data: date, time, cycles, and lbs of Reg, Nat, Col, Add.
Press VIEW,* to print all data. At end press 00 to clear data.
RCP: Enter and retrieve stored RECIPES.
BTCH: Blend a preset weight, fill a container and stop. View/Enter
Target Wt., Cur. Portion, Total, Batch Count. CE=clear
FAST: Increase Output. Run rapid FAST cycles after a weighed cycle.
Press * to toggle this function on or off.
TAG: Tag a Work Order and Operator number to all reports.
EXIT: Operational in ALL MODES. Press to EXIT any and all sequences.
CE: Press to display the "raw signal" weight readout for 3 seconds.

MANUAL MODE: to enter press: "*" then (11111) or your own password.
These additional keys are operational.

SET: Observe current settings, set by thumbwheel or keypad.
OPER: Operate all devices manually; open and close valves.
TIME: Operate devices for a timed period.
CAL: Operate devices for a preset time period to learn the rate.
NOTE: With above four keys also press one DEVICE key:
NAT, REG, COL, ADD, DUMP, ALARM, MIX, or HOLD.
ZERO: Zero the tare weight with the bin empty.
FULL: With bin loaded, enter gram weight to calibrate load cells.

*00 Clear DATA fields.
*99 Enable calibration of load cells.

PROGRAM MODE: to enter press: "*" then (22222) or your own password.
MANUAL operations plus these additional keys are operational.

SET: Enter settings using keypad; locks out thumbwheel use.
PARA: View or change system constants and parameters.

STAR FUNCTIONS: Press * and two numbers for the following functions:

*02 Extrusion and Yield Control. *66 GB/WSB I.D. number (1-255).
*05 Inhibit table clearing. *69 Regrind as second natural.
*11 DATE - TIME, real-time clock. *71 Color percent of blend.
*12 Move table from ROM to RAM. *72 Additive percent of blend.
*23 Move from RAM to EEPROM. *74 Stop, alarm MAX wt exceeded.
*32 Move from EEPROM to RAM. *75 Alarm on weight drop.
*25 ROM OK flag, "CE" to clear. *77 Print parameters.
*33 Special Alarms. *78 Change program mode PASSWORD.
*44 End cycle - bin full. *82 Precision Ratioing.
*45 Change MANUAL mode password. *87 VOLUMETRIC operation.
*47 Totalizer flag. *88 Print display readout.
*52 Double dump weigh bin. *89 Select pounds, kilos.
*54 Print cycle information. *98 Display raw weight number.
*57 For Liquid Color PIAD system

Use "*" key to select readout or toggle flags ON or OFF.

Page 26

Three (3) operation Modes are available; AUTOMATIC, MANUAL, PROGRAM.

KEYPAD - AUTOMATIC OPERATION MODE

This is the NORMAL operating mode. When power is turned on, the unit
is in this mode. Automatic dispensing occurs ONLY in this mode. The
AUTOMATIC mode is indicated by the ABSENCE of the letter "P" or "M" at
the left end of the display.

Only the VIEW, RECIPE, BATCH, FAST, TAG, *, CE, and EXIT keys are
available in this mode.
These keys operate BETWEEN cycles only or when the PAUSE switch is on.
To stop between cycles, use the "OFF AT END OF CYCLE" switch.

VIEW DATA: Press to display the CURRENT Date and Time, LAST CLEARED
(VIEW) date and time, and stored material usage data. Six totals
are available: (in Pounds, Kilos, Grams, or Ounces)

Number of CYCLES that have occurred: (CY= #####)
Weight of REGRIND that has been dispensed: (R = #####)
Weight of NATURAL: (N = #####)
Weight of COLOR: (C = #####)
Weight of ADDITIVE: (A = #####)
Total weight of ALL materials: (T = #####)

Each successive press of the VIEW key displays the next
total. The last displayed line will say (00=CLEAR) for 5
seconds. During this time, you may press 0,0 to clear the
data. Waiting 5 seconds or pressing any other key will exit
the sequence. When the sequence is exited, normal automatic
operation resumes. These totals may be displayed as pounds,
grams, kilograms, or ounces by a selection procedure
explained later (*89).

Press the VIEW key once followed by the "*" key to cause all
information to be sent to the printer (if available). To
then clear the data, press 00 within 5 seconds. Press any
other key or, wait 5 seconds, to continue the process
without clearing the totals.

RECIPE: This key allows you to LOOK at, RUN, and SAVE RECIPES.
(RCP) To SAVE a recipe you must be in the PROGRAM mode. Recipes
are thumbwheel switch settings. 100 recipes may be stored,
numbered 00 to 99.

This key is NOT FUNCTIONAL unless the 3rd digit of the "FLG"
parameter is set to 1 (xx1xx). To do this, see the SOFTWARE
MAINTENANCE section, PARAMETER TABLE, "FLG".

In normal Automatic mode: Press RCP key. If no RECIPE is
currently in use, display says (GET __). If a RECIPE is
currently in use then display will flash through the current
stored data:
(RCP __), (R = xx ), (C = xx.x), (A = xx.x)

Press CE to CLEAR CURRENT RECIPE and return to thumbwheels.

Page 27

Press RCP to look at another recipe. Display = (GET __).
Enter 2 digits to retrieve one of 99 recipes.
Display will flash through the current stored data:
(RCP __), (R = xx ), (C = xx.x), (A = xx.x), (*TO LOAD)

Press * to LOAD this recipe into memory.
Routine will exit automatically.
Press RCP or EXIT to return to the display (GET __).
Press RCP or EXIT again to exit.

To SAVE a RECIPE you must be in the PROGRAM mode.
If you press RCP key again after display of (GET __),
display says (SAVE __). Enter 2 digits, display will say
(SAVING ). The current settings are saved into memory
under the recipe number you have entered. These are
normally the THUMBWHEEL switch settings.

CAUTION: If settings have been entered by KEYPAD or RECIPE,
then these are the ones that will be saved. Therefore, when
saving a recipe, be certain that no other recipe is
currently loaded, and that no keypad-entered settings are
currently loaded. The lower right corner of 3 LEDs should
be off indicating thumbwheels are being read.

To clear a stored recipe, set all thumbwheel switches to
zero and enter these zero settings into the recipe location.

Routine will EXIT automatically.
EXIT will exit at any time.

When a RECIPE is loaded, three LEDs, (R, C, A, Locked
out) light indicating that the thumbwheel settings do not
represent the settings that are being run by the controller.
Whenever internally stored settings are not the same as the
thumbwheel settings, these three LEDs light to indicate this
condition. These LEDs correspond to REGRIND, COLOR, and
ADDITIVE settings respectively.

NOTE: To allow the operator the ability to stop running any
single component, a thumbwheel setting of all ZEROS (00.0)
can be accepted as valid to override any setting entered by
a Recipe. If you want this override option, enter a 0
(_SE 0xxxx) as the first digit in the SE parameter. The
default entry of 1 (_SE 1xxxx) indicates the override option
is turned off. See PARAMETERS; SE.

BATCH: This key allows you to blend a PRE-SELECTED WEIGHT of
(BTCH) material, and then STOP running and sound the ALARM. The
process may also be programmed to sound the alarm but
continue running. Since each cycle will always blend a full
weigh bin amount, the total amount blended may exceed the
target batch weight by up to one cycle's blend weight.

This key is NOT FUNCTIONAL unless the last digit of the
"FLG" parameter is set to 1 or 2 (xxxx1). To do this, see
the SOFTWARE MAINTENANCE section, PARAMETER TABLE, "FLG".

The ALARM SILENCE button on the side of the controller, is

Page 28

the ONLY way to CONTINUE OPERATION after a BATCH amount has
been run.

Assuming a proper "FLG" parameter is set:
Press the BTCH key once to view the desired BATCH WEIGHT.
Display will say (BW #####).
BATCH WEIGHT is the amount you wish to dispense before
stopping and/or sounding the alarm.

Press again to view the CURRENT PORTION, of the batch, that
has been dispensed.
Display will say (CP #####).
CURRENT PORTION shows how much has been blended so far.

Press again to view the ACCUMULATED TOTAL weight of all
batches dispensed.
Display will say (AT #####).
ACCUMULATED TOTAL is the sum weight of all batches that have
been blended. This number will continue to grow until it is
manually cleared to zero, or it exceeds its maximum possible
value.

Press again to view the total BATCH COUNT.
Display will say (BC #####).
BATCH COUNT is the total number of batches that have run.
This number will continue to grow until it is manually
cleared to zero, or it exceeds its maximum possible value.

Press again to return to normal operation.

When any of the above totals are being displayed, you may
press the CE key to RESET that number to zero. While all
four totals can be cleared to zero manually, only a BATCH
WEIGHT number can be entered manually.

When the BATCH WEIGHT is being displayed, you may enter a
NEW batch weight using the keypad. You must enter a 5 digit
number with leading zeros, if necessary. Maximum number
that can be entered is "59999".

The unit of weight that will be used is either POUNDS or
KILOGRAMS as determined by the *89 option, explained later.

While in operation, when the total is reached or exceeded,
the system will alarm and stop blending if the FLG parameter
is set to 00001. The system will alarm but CONTINUE running
if the FLG parameter is set to 00002.

Use the ALARM SILENCE button (on the side of the controller)
to silence the alarm. Pressing the BTCH key to view the
information will also silence the alarm.

If the system is programmed to STOP at the end of a batch,
the ALARM SILENCE button MUST be pressed to start blending
the next batch. The First press of the ALARM SILENCE button
will silence the alarm. The Second press will start the
next batch.

Page 29

NOTE: Fractional cycles are not blended. Total weight may
be in over the target by as much as one cycle weight.

The EXIT key will exit the BTCH sequence at any point but
will NOT cause the system to start a new batch.

If an additional 120 volt output is desired for an alarm,
substitute a 4 or 7 for the 00001. 4 turns on the Additive
outlet, 7 turns on component 7 output.

If you have a printer connected, totals will print
automatically. (see VIEW, * for details).

FAST: This key will allow you to exceed the normal blending rate
of your unit. Once your system has learned proper flow
rates of each material, the timing of each component
dispense is very consistent cycle to cycle. The FAST key
allows one or more FAST REPEAT cycles to follow a normal
calibrated cycle. In a FAST REPEAT cycle all components are
dispensed simultaneously, without any weights being taken.
Errors in dispense amounts will not be detected. These are,
in fact, volumetric dispenses, not gravimetric. These
dispenses take much less time. Throughput may be doubled in
this manner.

This key is NOT FUNCTIONAL unless the 4th digit of the "FLG"
parameter is set to 1 (xxx1x). To do this, see the SOFTWARE
MAINTENANCE section, PARAMETER TABLE, "FLG".

The shorter mixing time may be a problem. So the number of
FAST REPEAT cycles is kept as low as possible. Up to 4
repeats may occur.

After pressing the FAST key, use the * key to toggle the
FAST flag ON of OFF. When set to (FAST OFF) FAST mode will
not operate. When set (FAST ON) every normal calibrated
dispense will be followed by up to 4 FAST repeat dispenses.

Press * to toggle between (FAST ON) and (FAST OFF).
Press EXIT, to exit.

When the FAST mode is in operation, the display ( FAST)
will flash intermittently.

TAG: This key (third row, third key) allows three pieces of
information to be "tagged" onto all data that is either
printed or retrieved through the computer port. The items
are WORK ORDER, OPERATOR, and RECIPE number.

This key is NOT FUNCTIONAL unless the 2nd digit of the "FLG"
parameter is set to 1 (x1xxx). To do this, see the SOFTWARE
MAINTENANCE section, PARAMETER TABLE, "FLG".

Press once to display the current Work Order number
(WO-----). Press again to display the current Operator
number (OPRTR---). Press again for the Recipe (RECP ---).
You may enter or change the Work Order or Operator number
when each is displayed. Recipe number can not be altered.

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These numbers are for your TRACKING of information ONLY.
They have NO EFFECT on the operation of the Weigh Scale
Blender.

WORK ORDER number (6 digits) allows you to tag all
information with an internal accounting number such as a job
or purchase order number.

OPERATOR number (3 digits) allows you to track who is
operating the equipment.

RECIPE number (3 digits) allows you to track what recipe you
are using. The number will be a 2 digit number if a recipe
is being run that resides in the controller RAM; one that
was entered using the RECIPE key. If a recipe has been
enter using our MLAN software, through the computer port,
then a 3 digit number will be displayed. In any case, the
number in this field will be displayed and "tagged" to all
printouts and retrievals.

EXIT will exit the sequence at any point.

EXIT: Operational in ALL MODES to exit ALL keypad sequences.

CE: Press "CE" at any time to display RAW DATA readout of the
load cells for five seconds. This is helpful in diagnosing
possible load cell problems and is explained in detail in
the MAINTENANCE section.

Holding the "CE" key down while turning POWER ON will
perform a "CLEAR". See CLEAR ROUTINES section.

V/T and UP/DOWN ARROWS: Operate in the Extrusion Control Mode only.
Refer to Extrusion Control Supplement for their operation.

KEYPAD - MANUAL MODE

In this mode, you may operate individual functions manually for test
purposes. Calibration of Load Cells is also possible. No totals are
saved and automatic operation does not take place. The low level
sensor has no control or effect over manual operation requests.

The Row of keys marked SET, OPER, TIME, and CAL operate in this mode
coupled with the Column of keys marked REG, NAT, COL, ADD, DMP, ALRM,
MIX, and HOLD. ZERO and FULL keys allow Load Cell calibration.

You can enter this mode only when the controller is between cycles.
The sensor must be covered or the sensor control switch must be in the
"STOP - END OF CYCLE" position. When in this mode, no automatic
dispensing occurs.

TO ENTER THIS MODE: press "*", then enter the correct password number.
The correct password supplied with the unit is "11111." You may change
this to any other 5 digit number if you wish as explained later (*45).
When in the MANUAL mode, the letter "M" shows at the left end of the
display.

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