Conair GB- WSB User Manual

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Conair GB- WSB User Manual

Gravimetric

Blenders

GB and WSB models with 4-component control

Installation

Maintenance

Operation

Troubleshooting

Instant Access

Parts and Service

(800) 458-1960

(814) 437-6861

www.conairnet.com

The Conair Group, Inc.

One Conair Drive

Pittsburgh, PA 15202

Phone: (412) 312-6000

Fax: (412)-312-6320

UGB006/1103

Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided.

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.

Copyright 2003

THE CONAIR GROUP, INC.

All rights reserved

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 # 412-312-6227

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 THROUGHBOLTED 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.

Page 30

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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