Labotek FGB-M05, GraviMaster-FGB-M05 User Manual

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MANUAL

GraviMaster-FGB-M05 (S)

Gravimetric Blender

Serial No. ...................

ISO 08.01.02.064.GB

986731

Rev. May 2001

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1.0 INTRODUCTION

2.0 CONTROLS

2.1 Blender startup

2.2 Blender status

2.3 Machine-mode

2.4 Production-modes

2.5 Mixer-mode

2.6 Dispense modes

2.7 Batch handling

2.7.1 Production control

2.7.2 Recipe to weight calculation

2.7.2.1 Method Standard

2.7.2.2 Method Percentage

2.7.3 Adding extra materials

2.7.4 Additive to regrind

2.7.5 Regrind control

2.7.5.1 Empty regrind Control

2.7.5.2 Stock Silo Control

2.7.6 Dispensing

2.7.7 Calculations

2.8 Datalogging

2.9 Certiﬁ cates

3.0 USER INTERFACE

3.1 Operator-interface

3.1.1 Keyboard

3.1.2 User control

3.2 Recipes

3.2.1 Change components

3.2.2 Add/change recipes

3.2.3 Change current recipe

3.3 Timely information

3.3.1 Production screen

3.3.2 Material usage screen

3.3.3 Input & Output monitor

3.4 Adjustment of the gravimetric blender

3.4.1 Calibration of the weighbin

3.4.2 Tare of the weighbin

3.4.3 Hardware-reactiontime

3.5 Overview of parameters

3.5.1 Public parameters

3.5.2 Protected parameters

3.6 Reports and overviews

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3.7 Settings of the user-interface

3.7.1 Change the rights of an operator

3.7.2 Change entrycode

3.7.3 Change date and time

3.7.4 Revision code of the system

3.8 Menu hierarchy

4.0 INSTALLATION

4.1 Demanded connections

4.2 Attaching

5.0 ALARMS

5.1 Alarm reports and solutions

6.0 MAINTENANCE AND REPAIR

6.1 Maintenance

6.2 Replacement of parts

6.2.1 Replacement of printed circuit

6.3 Cleaning the machine

6.4 Transportation of the GraviMaster

7.0 TECHNICAL INFORMATION

7.1 General machine speciﬁ cations

7.1.1 Safety measures

7.2 User-interface speciﬁ cations

7.3 Valves speciﬁ cations

7.4 Air pressure cylinders speciﬁ cations

7.5 Electrical diagrams

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1.0 INTRODUCTION

GRAVIMETRIC FEEDING

An efﬁ cient materials blending system is an essential feature of the modern plastics processing industry. Dosing each component on the basis of weight shows distinct advanta ges over traditional volumetric systems. The quantity of material delivered is precise and unaffected by variations in bulk density, ﬂ ow characteristics and particle size.

Ferlin Plastics Automation now have a range of more than twenty blenders that deliver the beneﬁ ts of gravimetric blending at a price that makes other gravimetric ... and most volumetric systems ... look distinctly expensive.

FGB SERIES GRAVIMETRIC BLENDERS

“GraviMaster” blending systems are available in more than twenty diffe rent models with a throughput capacity range from 10 to 750 kg/hr for the standard units. The number of components on the standard unit is two to six. But purpose-built units may designed for additional feeds up to a maximum of ten and a throughput capacity up to 1500 kg/hr. The blending units may either ﬂ ow-control-valve design or have a combination with auger-feeders. The proven “GraviMaster” blending systems are being used successfully in Injection-moulding, Blow-moulding, Sheet-extrusion and Film-extrusi on.

ACCURATE WEIGH SYSTEM

Each component is dispensed into a weigh-pan using one set of load cells. When all the components are correctly weighed, the blend is discharged into a mixing chamber. A high efﬁ ciency horizontal mixer is programmed to give a uniform blend which discharges to a storage bin with suction device, or directly into the processing machine hopper.

The system is capable of extremely accurate measurements of additive, even at very small percentages or ratios. Load cells of the highest accuracy are used, weighing to within

0.01 gm. The accuracy of the process is enhanced by the software system which is designed to compensate in a subsequent batch for any errors arising in a prece ding batch. Overall accuracy of 0.1% can be achieved.

COMPACT AND MODULAR CONSTRUCTION

The units are designed and built as a modular construction using standard components where possible, so that all components are readily obtainable. All components which are in contact with the raw material are made in stainless steel. This includes hoppers, valves, augers, weigh pan, mixer and mixing chamber. When auger feeders are instal led, these can be quickly accessed for easy cleaning. The mixing chamber and weigh pan can be removed easily for cleaning and access. The construction is in accordance with the essential require ments under the CE regulations.

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RELIABLE PROCESS CONTROL

The FGB control system incorporates the latest in computer and micro processor technology for total automation of recipe entry and stora ge, inventory control and process monitoring. The control panel (user-interface) is provi ded with a micro-controller and industrial PC with LCD-display, functional keyboard, ﬁ ber optic communication cable (or RS-422) and parallel printer port.

Features are:

• data storage of all plant raw materials.

• easy call up of materials for the formulation of recipes.

• fast identiﬁ cation of recipes and call up for machine operation.

• automatic regrind control within chosen limits, so that regrind generation is matched

with usage.

• automatic additive to regrind control.

• a ﬁ xed weight of blended material can be produced according to any of the stored

formulations.

• screen display of all process operation.

• reports of material used and batch histories can be printed on an optional printer

regularly.

• storage facility for components and recipes.

• functions are menu driven and take the operator through the required sequence of

actions with simple instructions.

• the software is pre-programmed with many options for the future, these are blenders you won’t outgrow.

Options are:

• automatic stock silo control.

• extra level control of the blender hoppers.

• extra level control of the machine hopper.

• control and data for materials management systems.

• different language on the display.

• automatic loading of the hoppers can be provided separately with Ferlin loaders or

others of your choice.

• several blenders may be linked to a central user-interface to give integrated inventory control over the whole process.

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2.0 CONTROLS

When all components are available the dispense of a batch starts. The cycle begins with closing the weigh-pan. Then each of the requested components is dispensed and weighed in the weigh-pan. When all the components of the recipe are correctly weighed, the blend is dischar ged into the mixing-chamber. A horizontal mixer mixes the compo nents to a uniform blend which discharges to a storage bin, or direct ly into the machine hopper.

2.1 Blender start-up

In this section is a short description of the normal start-up action of the blending system. More details of the controls are described in the following sections. An emergency stop

can be made to shut-down the machine by pushing the button as indicated in drawing 1 in § 7.7.1.

Steps to follow for the start-up of the blending system:

[1] Plug the communication cable into the user-interface and control box on the blender. [2] Connect air pressure to the blender and turn it on, 6 bar is recommended. [3] Turn on the power. On the user-interface and control-box. [4] Select the right language. The selected language is indicated. Select a different language through key <↑> or <↓> and press <ENTER>. [5] If necessary adjust date and time. [6] Select the blender to be started. [7] Select on the interface the desired recipe from the menu (F1)

‘controller / select recipe’

[8] Be sure there is no alarm active. [9] Start the blender, press <START>.

The blender will now operate automatically on the select recipe.

2.2 Blender status

The control of the blender is based on a number of status. Each status gives an exact description in which situation the controller is. The controller knows the following status:

Inactive

At the start-up of the blender several internal tests will be done automatically if the controller can’t ﬁ nd a recipe. In this status the blender will not start until a recipe is edited.

Standby

The blender is complete in rest but can be started any moment by giving the start-command. In this status recipes, parameters and debug-commands can be sent to the controller.

Operating

The blender will now produce a blend for the selected recipe.

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Pause

When the pause-command is given for a temporary stop the blender will stop after the cycle is complete.

Stop requested

The blender is operating but has received a stop-command. The stop-command will be executed at the end of a batch-cycle. This status will be replaced automatically with ‘standby’ if nothing is done. If a start-command is given during the status ‘stop requested’ the status will be ‘operate’ again.

Error The controller has detected an error and therefore the system will stop. In a sub-menu at the operator-interface the error will be displayed. The error situation can be recovered using the <ENTER> command. The error must be solved then.

2.3 Machine-mode

The controller can be in two modes: Automatic and Manual. The operator can change the mode using the menu item ‘controller’. This changing of mode is only possible while the blender has status ‘standby’.

If a controller is in Automatic-mode, the recipe will be executed without the need of an operator. This mode is used for production purposes and is only dependent on the settings ‘production-mode’.

In automatic mode the keys mentioned below mean: F5 Start-command (start-key) F6 Stop-command (stop-key) F7 Pause-command F8 Continue-command (clear pause)

After a start-command in Manual-mode one batch will be executed. After this the machine status will be ‘standby’ again. The weighbin and mixbin-valve can be controlled manually.

In manual mode the keys mentioned below meaning: F5 Step-command (One component of a batch) F6 Reset-command (Back to the ﬁ rst component of a batch) F7 Empty weighbin F8 Empty mixbin

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2.4 Production-modes

The production-mode of the blender indicates how the production will stop in automatic mode. This parameter can be changed using the menu (F1) ‘controller / public parameters’. The production-mode has three options:

Continue

The blender will not stop automatically after the start-command. The blender will continue the production, unless the blender runs out of material or an error occurs.

Weight->Alarm

If ‘Weight->Alarm’ has been chosen, a requested weight has to be given. After a start the requested weight will be compared with ‘produced-weight’. If both are the same or the ‘produced-weight’ higher, the controller will send an alarm to the operator-interface. The production will continue.

The alarm can be recovered setting the ‘production-weight’ to zero (0). This command is part of the option-menu (F2) of the status screen.

Weight->Error

When using the option ‘Weight->Error’ a weight has to be given. After a start the requested weight will be compared with ‘production-weight’. If both are the same or the ‘production-weight’ higher, the controller will send an error to the operator-interface. The production will not continue in this case.

2.5 Mixer-mode

When all components are dispensed, the contents of the weighbin will be emptied. The mixer in the mixing chamber, which contains the dispensed components, can be put in different modes. Choose the menu (F1) ‘controller/public parameters’.

Normal

The mixer is off during production. If the components are dumped from the weighbin into the mixer chamber the mixer will be on for a predeﬁ ned number of seconds, deﬁ ned by ‘mixerOnTime’. This parameter can only be changed if this option is chosen.

Pulsing

The mixer will pulse during production. Both on- and off-time ca be deﬁ ned using the parameters mixerPulseOnTime (time on) and mixerPulseOffTime (time off). These parameters can only be changed if this option is chosen.

Off

The mixer is always off.

The mixer is always on, when the machine status is active.

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2.6 Dispense modes

The blender has two ways of dispensing: gravimetric and volumetric. One mode can be selected or a combination of both. This can be deﬁ ned choosing menu (F1) ‘controller / public parameters’.

Gravimetric

All component of the batch are dispensed and measured separately. Gravimetric is more accurate than volumetric, but takes more production time, ie., lower output.

Volumetric

All components of the batch are dispensed at the same time using the dispense time of each component (calculated by the system). The components are dumped directly in the mixer chamber. No measurement is done in this mode. Therefore this method is less accurate, but the production time is faster, ie., maximum output

Combination

When combination is deﬁ ned, one gravimetric will be followed by a deﬁ ned number of volumetric dispenses. This is deﬁ ned by the parameter combinationRatio. This parameter can only be deﬁ ned if ‘combination’ is chosen. This mode has the best of gravimetric and volumetric.

Use: normally the deﬁ ned combination will be done (ex. 1:3). However, if the mixer chamber is full, the process will automatically do a gravimetric dispense instead of a (possible) volumetric one.

2.7 Batch handling

2.7.1 Production control

If a start command is given the controller will check if the blender actually can start. If a hopper has a low-indication (optional) the controller will alarm.

Also the parameters are checked. These can be in conﬂ ict with the recipe to be executed. The following items will be checked (if applicable):

* Empty Regrind control

- The controlled hopper must contain regrind (according to recipe)

* Stock silo control (optional)

- Controlled hopper must contain regrind (according to recipe)

* Additive to regrind

- Controlled hopper must contain additive (according to recipe)

The blender will not start unless all conditions are met. A message will be sent to the user interface.

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2.7.2 Recipe to weight calculation

After a start-command the controller will calculate the requested weights of all components of the selected recipe.

A recipe can be deﬁ ned in two ways: ‘Standard’ and ‘Percentage’. These methods can be deﬁ ned in the recipe choosing menu (F1) ‘recipes / edit recipes’. The methods ‘Standard’ end ‘Percentage’ deﬁ ne the relation of the components (Regrind, Natural and Additive) in a recipe.

2.7.2.1 Method Standard

The different components are deﬁ ned as follows:

Regrind : Percentage of the batch weight Natural : Relation between other naturals Additive : Percentage of the totals of all naturals

Example

Batchweight 2000.0 gr. Regrind 20.0% Natural 1 4 Natural 2 1 Additive 5.0%

Regrind : 20.0% of 2000.0 gr. 400.0 Naturals : naturals + additive = 80.0% naturals + (0,05 * naturals) = 80.0% naturals = 80.0/1.05 = 76.2%

natural 1 = 4/5 * 76.2 = 61.0% 1220.0 natural 2 = 1/5 * 76.2 = 15.2% 304.0

Additive : 80.0 - 61.0 - 15.2 = 3,8% 76.0

TOTAL 2000.0

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2.7.2.2 Method Percentage

The different component are deﬁ ned as follows:

Regrind : Percentage of the batch weight Natural : Percentage of the batch weight Additive : Percentage of the batch weight

Total sum must be 100%.

Example

Batchweight 2000 gr. Regrind 20.0% Natural 1 60.0% Natural 2 15.0% Additive 5.0%

Regrind : 20.0% of 2000.0 400.0 Natural 1 : 60.0% of 2000.0 1200.0 Natural 2 : 15.0% of 2000.0 300.0 Additive : 5.0% of 2000.0 100.0

TOTAL 2000.0

2.7.3 Adding extra materials

The deﬁ ned amount of the component deﬁ ned in the recipes can be changed external using some special parameters. The controller has two methods: ‘Additive to regrind’ and ‘Regrind Control’.

IMPORTANT

Addition of extra material using ‘Additive to regrind’ and ‘Regrind Control’ is only

possible when a ‘standard’ recipe is used.

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2.7.4 Additive to regrind

It is possible to dispense more additive in relation to the amount of regrind. Choose for this deﬁ nition menu (F1) ‘controller / public parameters’. A maximum of two hoppers (additive) can be deﬁ ned (additiveToRegrindHopper). The deﬁ nition must be completed deﬁ ning the requested percentage (additiveToRegrindPerc).

ADDITIVE TO REGRIND

Not activated Activated with 2.0%

Component Recipe Weight (g) Recipe Weight (g)

Regrind 20.0% 400.0 20.0% 400.0 Natural 1 4 1219.0 4 1213.0

Natural 2 1 304.8 1 303.2 Additive 5.0% 76.2 5.0% + 2.0% 83.8

2.7.5 Regrind control

The ﬂ ow of ‘regrind’ is very often not continuous due to the process. There are two methods to adjust the amount of regrind to the actual process: ‘Empty Regrind’ or ‘Stock Silo’.

2.7.5.1 Empty regrind Control

Empty regrind control means: keep the regrind-hopper empty. The material must be dispensed, because otherwise another parts of the process can be destroyed (regrind return mechanism).

Through menu (F1) ‘controller / protected parameters’ the process can be activated. After the process is started a deﬁ ned amount of batches (Empty regrind wait count) must be awaited before the percentage will be increased. The percentage will be increased in the deﬁ ned number of steps (Dispensevariation cycl.) until the requested percentage is reached (Dispense increase).

If not enough material can be dispensed from the regrind hopper, then regrind will be reset to the original setting (recipe).

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2.7.5.2 Stock Silo Control

A regrind silo can have (optional) three sensors to detect high- low- and middle. If the controller has these sensors, ‘Stock-Silo’ regrind control can be activated, choosing menu (F1) ‘controller / protected parameters’.

If the high-sensor is true, the silo is almost full. Therefore more regrind will be dispensed. This is the same as described in ‘empty regrind control’. This will be done until the middle sensor is not true anymore. In a deﬁ ned number of steps the process will dispense the original setting of the recipe.

If the low-sensor is true, the silo is almost empty. Therefore less regrind will be dispensed. This is the inverse as described in ‘empty regrind control’. This will be done until the middle sensor will become true. In a deﬁ ned number of steps the process will dispense the original setting of the recipe.

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2.7.6 Dispensing

Dispensing of the different components will start after the calculation of the related weights. The components are dispensed in the order as deﬁ ned in the recipe (gravimetric only). In volumetric mode all components are dispensed at the same time.

Every mechanical valve has a reaction time. The controller uses the ‘Hardware Reaction Time’ to calculate the time which the dispense valve must be activated. The ‘Hardware Reaction Time’ is the maximum active time of the valve when no material is dispensed. The controller uses a pulse of 5ms in the following algorithm:

OpenTime = Weight [g] / dipenseSpeed [g/s]

OpenPulses = (OpenTime [s] / 0.005 [s]) + HardwareReactionTime [Puls]

After every dispense cycle the weight is measured. The weight bin must be stable before the weight can be measured, therefore a time delay is inserted between dispense and measuring. When the controller starts measuring the signal must be stable for at least 1 sec. (signal within the ‘Weighbin-variationband’)

After measuring the weight of the ﬁ rst dispense some calculations can be done, and with the results parameters can be changed. Result is a more accurate next dispense. After the ﬁ rst dispense of a material one of the following situation occurs:

Dispense is correct

The difference between calculated- and measured weight is less then the dispense accuracy. In this case extra dispense tries of this material are not necessary.

Dispense not correct (too little)

The difference between calculated- and measured weight is more than the dispense accuracy but there is less dispensed (measured) than calculated. In this case the controller reacts according to the chosen ‘alarm-type’. The following ‘alarm-types’ are possible:

IGNORE No extra dispense-tries. Relations within the recipe will corrected by re-calculations.

WARNING The controller tries to reach the dispense-accuracy by extra dispenses. The extra dispenses are limited by the parameter ‘dispenseTry’. When after a maximum number of dispense tries, the accuracy is not reached the controller sends a warning only to the user (= The controller continues with the next material).

ERROR The reaction of the controller is equal to ‘WARNING’ only an error is sent to the user when the accuracy is not reached. Now the controller waits for a conﬁ rmation (enter) to initiate new dispense tries of the same material. This process goes on until the dispense accuracy is reached.

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Dispense not correct (too much) To much material has been dispensed so there is nothing the controller can do. Of course the relations within the recipe will corrected by re-calculations.

After the ﬁ rst dispense try in all of the above mentioned cases a new dispense rate will be calculated. If the measured dispenserate (measured weight / dispense time) differs from the used dispenserate a correction can be made. A correction is only made if the difference between the measured- and used dipenserate is less then the boundary (dispenseRateVarBand). This method prevents the controller calculating incorrect values e.g. if a hopper runs out of material. The new dispenserate is calculated by the next algorithm:

dispenseRate = ((4 * dispenseRate) + (measuredWeight/dispenseTime))/5

When all components of a recipe are dispensed the contents of the weighbin is dumped in to the mixer chamber. The weighbin dumps the material by opening a valve for a given time. This time (weighbinDumpTime) is a parameter which can be changed. It is also possible to start the mixer at this time (see mixer-mode). There are two conditions for opening the weighbin valve:

Condition 1. The mixbin-vale may not be open (if present)

Dispensed material must be mixed ﬁ rst before it can be used. Therefore the mixbin-valve and weighbin-valve may not be open at the same time.

Condition 2. The mixerchamber may not be full

If the input-device indicates a full mixerchamber no material may be dumped into it (it is full)

2.7.7 Calculations

In order to be able to dispense with high accuracy, the actual measured weights will be used to recalculate the requested weight of the next component. The dispense will be optimised if possible in order to guarantee a good batch (good relation).

IMPORTANT

Best dispense order is:

Regrind, Natural, Additive

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2.8 Datalogging

Some production data is stored. This is shown at the user interface and can also be printed.

* Batch data

- measured weight (each component)

- dispenserate of each component

- recalculation to recipe

* Total data

- Sum of batch data

* Material usage

- dispensed amount of each hopper

- percentages

The controller saves all data in battery-backup memory.

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2.9 EQ-Net Certiﬁ cate

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2.10 ISO Certiﬁ cat

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3.0 USER INTERFACE

3.1 Operator-interface

3.1.1 Keyboard

Description:

F1 Open main menu. All other sub-menu’s can be selected F2 Open option menu. The contents is dependent of the actual screen. F3 Will be used during calculation F4 Choose node number

The function keys F5 up to F8 is dependent of the machine mode (automatic, manual).

FUNCTION KEY IN MACHINE-MODE Function key Automatic Manual F5 Start production Dispense one component F6 Stop production Mixer F7 Pause Dump weightbin F8 Start after pause Dump mixer chamber

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Besides the function key there are some special keys:

DIRECT MACHINE-CONTROL KEYS Key Description

# or F4 Select FGB

START Start command, the same as F5

STOP Stop command, the same as F6

DATA ENTRY KEYS

Key Description

0-9 Entry of numbers

+/- Increase and decrease function (value of ﬁ eld can be changed by step)

ENTER Select function. (choise is made and entered values are saved)

. Decimal point

ESC Escape, Leave menu without choice

(Home) (Arrow up with line) Jump to ﬁ rst element of row

(End) (Arrow down with line) Jump to last element of row

INS Insert function to add recipes and components

DELL Delete function to delete recipes and components

← Backspace (above DELL-key) delete the character left of the cursor

← ↑ → ↓

Cursor-keys, move cursor and menu-items

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3.1.2 User control

The user-interface consists of several screens which can be selected by a menu. A screen consists of objects only one object in a screen is active (selected). By using the ↓ en ↑ arrow keys the actual selected object can be changed. Pressing <ENTER> activates the selected object.

Button

After activating the button a command (or set of commands) is (are) executed. The name of the button represents the functionality of the button.

Number input ﬁ eld

When a number input ﬁ eld is selected it can be activated by either the <ENTER> key or just typing the numbers. The activated input ﬁ eld shows a cursor at the position where the next number will be placed. To deactivate (leave) the input ﬁ eld use one of the the following keys <ENTER>, <ESC>, ↓ or ↑

Text input ﬁ eld

The text input ﬁ eld is equal to a number input ﬁ eld but it also accepts characters. Because the keyboard doesn’t have character-keys a special method is implemented to enter characters.

To enter a character in a text inputield ﬁ rst activate the object with the <ENTER> key. When the input ﬁ eld is activated a cursor is shown at the ﬁ rst position. At this moment it possible to select a character with the <+> and <-> keys. After a character is chosen the next position can be selected with the → arrow key.

Option ﬁ eld

Option ﬁ elds are objects with a toggle function (yes/no) or (true/false). When the button according to the option ﬁ eld is activated the value is toggled. The actual value of the option ﬁ eld is displayed by a cross. When the cross is visible the object has the value ‘yes’ or ‘true’ otherwise the value is ‘no’ or ‘false’.

Optionlist

Optionlist ﬁ elds are ﬁ elds that can contain a limited set of values. The optional values become visible as the object is activated. Now the required value can be selected by using the ↑ and ↓ key and select it with <ENTER>.

3.2 Recipes

Recipes constitute the core of the controller. They contain all information about the material to be produced. By the menu (F1) ‘recipes / edit recipes’ it is possible to add recipes to the controller. One recipe consists of one or more (max 12) components which can be changed independently.

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3.2.1 Change components

There is a components list available in the controller. The list can be used by the operator to deﬁ ne recipes. The components list stores the name and type of a component and is maximised to 100 components. The operator is free to chose a name for a component. There are only three options namely:

Regrind Scrap-material Natural Basic-material Additive Additive-material (e.g. masterbatch)

One component of every type is already present in the list. These components have the name ‘no name’ and can not be deleted from the list.

To add or modify components chose the menu (F1) ‘recipes / edit components’. The next screen will be displayed:

[0]OPERATING AUTO[ ] [ ] [ ]

STATN:[0] FGB#00: (No name) STATUS OPERATING MODE: AUTOMATIC

------------------------ [Edit components] Name Type

SCR GARDEN CHAIR REGRIND ADEG-2RN NATURAL ADEG-4RN NATURAL ANTISTATIC ALU ADDITIVE

<ENTER> = edit component <INSERT> = insert component <DELETE> = delete component

F1Menu F2Option F3 F4Clear F5Start F6Stop F7Pauze F8Cont.

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In the screen it is possible to select a component with the arrow keys. After a component has been activated by <ENTER> the name and type can be changed. If the ﬁ eld type has been activated an option list will appear. One of the options (Regrind, Natural or Additive) must be chosen.

By pressing the <INS> insert-button a new component will be added to the list. The controller places a standard name and type into the ﬁ elds. The operator now can change these ﬁ elds to the correct name and type.

Deleting a component from the list can be done by pressing the <DEL> delete-key. The

component pointed to by the highlighted line will be deleted from the list.

The option-key (F2) contains two functions in the screen ‘edit components’: print components and search components, activate one of them by selecting and push <ENTER>.

Example: Add a new component

Goal: Component with he name “WHITE” and type “ADDITIVE”

Actions:

Step: Menu (F1) ‘recipes’ <ENTER>

Step: ‘edit components’ <ENTER> (By using the arrow-keys)

Name Type

Step: Press <INS> key (INS = insert)

Name Type < > [NATURAL]

Step: Search for the character W by using the + or - key: <+> Starts with special characters and numbers then the alphabet <-> Starts at the end of the alphabet When the + or - key is hold down the character will change fast.

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If the character W has been found the ? key is pressed.

Name Type <W> ? [NATURAL]

Step: Repeat the same procedure for the character H, I, T and E. When the whole name is given press <ENTER>. Now the name ‘WHITE” is stored.

Name Type ?WHITE? [NATURAL]

Step: Press the ? key again to select the type-ﬁ eld.

Name Type [WHITE] NATURAL ?

Step: Press <ENTER> to activate the ﬁ eld.

Name Type [WHITE] [NATURAL ] REGRIND NATURAL ADDITIVE

Step: Select ADDITIVE by using the arrow keys and conﬁ rm by pressing <ENTER>.

Name Type [WHITE] ?ADDITIVE ?

Step: To conﬁ rm the new component press the arrow key ? or use the <ESC> key.

Now the “ADDITIVE” component “WHITE” is added to the list. The maximum number of components is 100.

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3.2.2 Add/change recipes

The terminal has the capacity for 340 recipes. This space is divided into 4 spices so every connected FGB can contain 85 recipes. If the menu item (F1) ‘recipes / edit recipes’ is chosen a list with recipes will be displayed.

Now recipes can be added, changed or deleted. The <DEL>-key deletes the current recipe of course there will be a conformation for the operator. By adding <INS>-key or changing <ENTER> the current recipe the same screen is used.

[0]OPERATING AUTO[ ] [ ] [ ] STATN:[0] FGB#00: (No name) STATUS OPERATING MODE: AUTOMATIC +--------------------------EDIT RECIPE Number : [ 10] Name : CRATE Colour : [YELLOW ] Batch : [ 2]Kg. Interpretation : [STANDARD ]

H# Component Quant Alarm Rate (g/s) 1 noname (r) 50.0 IGNORE 957.2 2 noname (n) 2.0 IGNORE 891.4 3 noname (n) 2.0 IGNORE 875.5 5 noname (a) 4.0 IGNORE 8.3 4 <ENTER> = edit line 5 <INSERT> = insert line 6 <DELETE> = delete line 7 <HOME> = sort up 8 <END> = sort down 9 10 11 12 +-------------------------------------------------------------------------

F1Menu F2Option F3 F4Clear F5Start F6Stop F7Pauze F8Cont.

All ﬁ elds of the recipe are visible in the screen. By selecting the objects with the arrow-keys and activate them with the <ENTER>-key it is possible the change the them. Below a list is given with every ﬁ eld of the recipe giving some extra information about the ﬁ eld.

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FIELD OF A RECIPE

Fields Description Number Unique recipe number Name Recipe name Colour Characterﬁ eld for the colour-name Batch Total batchweight

Interpretation Recipe calculation

Component Link hopper to component

The screen can be left by pressing the <ESC>-key. Now the terminal checks the recipe and if it is correct it will be stored. If the recipe is not correct the operator can chose either changing the recipe or discard all changes.

The option-key (F2) contains other functions in the screen ‘edit recipes’. The next functions are available:

OPTION MENU IN EDIT-RECIPE

Option Description Copy recipe Copies the recipe to the same or other terminal.

Find number Searches for the recipe with the given number. Find colour Searches for the recipe with the given colour. Find name Searches for the recipe with the given name.

Print recipe Sends the current recipe to the printer. Print all recipes Prints all recipes of the actual controller.

Example: Add a new recipe

Goal: Add a 2 kg standard recipe . Remark: The required component names should have been added.

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Actions: Step: Menu (F1) ‘recipes’ <ENTER> Step: ‘edit recipes’ <ENTER>

Name Nr. Colour

Step: Press the <INS> key (INS = insert)

Number: [1] Name: ? ? Colour: [ ] Batch: [ 2.0] kg Interpretation: [ STANDARD ] H# Component Quantity. Alarm Speed (g/s) 1 2 : : 10 11 12

The name and colour of the recipe is entered in the same way as the components name (§ 3.2.1).

Step: Press the arrow key <↓> to select the batch.

Batch: < 2.0> kg

When the batchweight must be changed it can be done by the use of the numeric-keys

IMPORTANT Never enter a batchweight higher then the standard value.

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Step: Press the arrow-key <↓> once

Interpretation: < STANDARD>

Step: When the interpretation must be changed into PERCENTAGE press the <ENTER> key. Now select PERCENTAGE with the arrow keys and conﬁ rm with <ENTER>.

Interpretation: STANDARD

PERCENTAGE

Step: Press the arrow key <↓> once.

H# Component QTY Alarm Speed (g/s) 1 2 : 12

Step: Select the hopper you want to edit with the arrow-keys and press <ENTER> to activate.

H# Component Quantity Alarm Speed (g/s) 1 2 : 12

Step: Press <ENTER>.

Name Type Noname REGRIND Noname NATURAL Noname ADDITIVE WHITE ADDITIVE

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Step: Use the arrow-keys <↓> to select a component and press <ENTER>. Use the arrow-key <?> to select Quantity. Enter the quantity and press <ENTER>. Use the arrow-key <→> to select Alarmtype and press <ENTER>.

Alarm Ignore Ignore Warning Error

Step: Select an alarm type by using the arrow-keys and press <ENTER>.

It is not necessary to enter a speed (g/s) because the terminal already has entered standard values and the GraviMaster calculates new speeds and updates the recipe.

Step: Press the arrow-key <ο> to select the next hopper number.

Depending on the model, it is possible to use upto 12 hoppers.

The terminal has a keyboard but the keyboard doesn’t contain characters. Therefore it is possible to connect a standard AT keyboard to the terminal. This keyboard must connect to a connector which is placed on the PCB in the terminal. When using a AT keyboard, than:

• Switch power off the terminal

• Disconnect the internal keypath from the PC board

• Connect the AT keyboard on the PC board

• Switch on the terminal

Now you can use the AT-keyboard. When you are ready, than connect the terminal-keyboard again. This has to be done when the terminal is switched off.

3.2.3 Change current recipe

When an operator wishes to produce a new product a change of the current recipe must be done. To change the current recipe select menu (F1) ‘controller / select recipe’. The terminal now shows a list with all recipes. The recipe which is marked with an <↓> is the actual recipe, this recipe is also loaded in the controller.

IMPORTANT

When a new recipe is selected be sure that all hoppers are ﬁ lled with material. The controller calculates new dispense-rates by a fast algorithm in the ﬁ rst 5 batches.

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3.3 Timely information

It is possible to get an over view of one of the connected controllers. Therefore three screens are available on the terminal: production-screen, material usage-screen and input/output screen.

3.3.1 Production screen

The production-screen can be reached by selecting menu (F1) ‘production / production status’. The production-screen displays information about the current controller. The

information on the screen is updated every 0.3 sec.

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OPERATING AUTO[ ] [ ] [ ]

STATUS:[0] FGB#00: (No name) STATUS OPERATING MODE: AUTOMATIC

PRODUCTION STATUS]

Production mode :

CONTINUE Dispense mode: GRAVIMETRIC

Name: PIR-HOUSING Mix mode : PULSE

Recipe CRATES YELLOW

[current] [previous] [total]

H# Type Recipe Requested Dispensed Recipe Dispensed Recipe Dispensed

1 REG [ 20.0] 400.0 20.0 400.0 20.0 1600

2 NAT [ 1.0] 1523.8 1.0 1523.8 1.0 6095

3 ADD [ 5.0] 76.2 5.0 76.2 5.0 305

totals

[ACCEPT] [UNDO CHANGES] 0.1 2000.0 8000

Produced weight: 82000

F1Menu F2Option F3 F4Node F5Start F6Stop F7Pauze

F8Cont.

During production it is possible to change the recipe without a change of the current recipe. The recipe can be changed in the production-screen by selecting a ﬁ eld (arrow-keys). Next enter a new value and press <ENTER> to conﬁ rm. Now the recipe is changed but the controller uses the new values at the start of a new batch.

3.3.2 Material usage screen

The material usage screen menu (F1) ‘production / material usage’ displays the total quantity of material witch is used ordered by hopper number. The quantities which are stored doesn’t depend on the current recipe. The material usage screen is erased from memory by one of the following actions:

* Command given by the operator * After a operator prints the screen.

This is possible by using option-key (F2) and selecting the option you require and pressing <ENTER>.

Other values witch are stored in the material usage screen are: date of the last erase-action, number of batch-cycles and production speed (kg/hour).

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3.3.3 Input & Output monitor

The input & Output screen menu (F1) ‘controller / digital I/O monitor’ displays all digital input and output lines. Every object in the screen can be selected by using the arrow-keys. When a output line is selected and <ENTER> is given the digital output will toggle. The operator has control of the digital outputs when the controller is in ‘manual mode’.

3.4 Adjustment of the gravimetric blender

The controller has some system-parameters. These parameters must be entered during the installation of the GraviMaster. The controller uses these parameters to read the weigh bin signal correctly, to open the weigh bin-valve, control the dispense-valves or motors etc.

3.4.1 Calibration of the weigh bin

The controller uses two known (entered) calibration-points to calculate a weighline. The controller uses this line to ﬁ nd a weight by every input-signal. The two calibration-points must be entered by the operator by the menu (F1) ‘controller / calibration / loadcell’.

The calibration-procedure of the loadcell has two steps. Extra information is given to the operator by every step. This information is displayed at the top of the screen. First be sure that the weighbin is empty and press (F3). The weight of the empty weighbin is measured and stored by the controller. Next step is to ﬁ ll the weighbin with a reference-weight and be sure that the input ﬁ eld on the terminal has the same value. Now press (F3) again and the second calibration-point is measured and stored. The calibration-procedure is now ready.

IMPORTANT

The second calibration-point must be greater then the ﬁ rst one.

3.4.2 Tare of the weighbin

Due to temperature, age, overload etc. it is possible that the weighline of the controller ‘moves’. When the line has moved a zero-weight will be displayed that isn’t zero. To move the weightline back it is possible to start a new calibration procedure. But the calibration procedure takes a lot of time and the weightline is correct (it only moved). The tare-function moves the line back to its zero-point. To start the tare function enter menu (F1) ‘controller / calibration / loadcell-tarration’.

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3.4.3 Hardware-reactiontime

The adjustment of the number of pulses is very important for the autopulse system of the FGB-M05. When dosing less than 8 gram of material, the GraviMaster will switch over to the autopulse system. In the hardware-reactiontime the opening time can be adjusted by increasing the clockpulses. One clockpulse is 5 ms (0,005 s). The autopulse system does not caculate the rate in g/s but in g/puls. It calculates how many pulses he needs for an amount of material. This is why it is very important that the opening time of the pulse is not too long, because it cannot dose accurate anymore.

Standard adjustment:

Hopper

Clockpulses

Time (s)

1 3 0,015

2 4 0,020

3 4 0,020

4 3 0,015

3.5 Overview of parameters

The controller has a great number of parameters. The parameters are necessary to control the machine with all its features. The parameters are broken down into two groups; public parameters and protected-parameters. Free parameters may be changed by an operator, protected parameters may only be changed if the password is given.

3.5.1 Public parameters

Below a list is given of all parameters which are attainable by the menu (F1) ‘controller / public parameters’.

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PUBLIC PARAMETERS Parameter Description Init

AlarmReport Indicates if alarm-reports must be printed. No

ProductionReport Indicates if production-reports must be printed. No

If so the parameter interval-time must be given also. Interval

Pauze (time) before printing the next production-report.

01:00.00

BatchReport Indicates if batch-reports must be printed. No

ProductionMode Actual production-mode. There are three possible CONTINUE modes; CONTINUE, WEIGHT and ALARM_ WEIGHT. If the mode WEIGHT os ALARM_ WEIGHT has been selected the parameter production Weight must also be given. ProductionWeight The FGB stops his production when the production 100 [Kg] Weight is reached. (productionMode must be WEIGHT or ALARM_WEIGHT). DispenseMode Actual dispense-mode. There are three possible GRAVIMETRIC modes; GRAVIMETRIC, VOLUMETRIC and COMBINATION. If the mode COMBINATION is

chosen the parameter combinationRatio must be given. CombinationRatio Relation between the volumetric and gravimetric 3 dispenses. (one gravimetric dispense and x volumetric dispenses). MixMode Actual mixermode. There are four possible modes; PULSE ON, OFF, NORMAL and PULSE. In normal-mode the parameter mixerOnTime must be given. In the mode pulse the parameters mixerPulseOnTime and mixerPulseOffTime must be given.

MixerOnTime Time the mixer is activated after the material is 10 [s] dumped out of the weighbin.

MixerPulseOnTime Time the mixer is activated in pulse-mode. 5 [s]

MixerPulseOffTime Time the mixer is not activated in pulse-mode. 15 [s] AdditiveToRegrind Percentage additive to regrind which must be added. 0 [%] Percentage 1/2 AdditiveToRegrind Hoppernumber in which the additive is. Hopper 5 Hopper 1/2

WeighbinDumpTime Time the weighbinvalve is activated (dumping of 4 [s] 0,5 kg unit material into the mixerchamber). 6 [s] 1,2,5 and 25 kg unit

LevelControlWaitTime Time between the full signal of the mixerchamber 8 [s] sensor and opening the mixerchamber-valve.

LevelControlDumpTime Time between the free signal of the mixerchamber sensor and closing the mixerchamber-valve. 1 [s]

*) No = [ ], Yes = [X]

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For example if the alarm report must be activated. First select the option ﬁ eld by using the up- and down-keys. Now press <ENTER> to activate the option ﬁ eld. If the option ﬁ eld displays a [X] the alarm report is activated. The parameters must be updated into the controller, so select the OK button and activate it by pressing <ENTER>. Updating the parameters into the controller must be done for every parameter.

3.5.2 Protected parameters

Below a list is given of all parameters with are attainable by the menu (F1) ‘controller / protected parameters’.

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PROTECTED PARAMETERS Parameter Description Init BatchWeight Total weight of one batch. This value is copied into 0,5 [kg] every recipe when it is created.

DispenseTry Maximum number of tries per component to reach 4 maximum accuracy

DispenseAccuracy Minimum accuracy for each component. 25 [%]

DispenseRate Maximum deviation when a re-calculation of the 30 [%] CorrectionBand dispense-speed is done

SiloPresent Indicates the ‘Stock-Silo’ regrind control process No is activated. MaximumTare Maximum absolute deviation from the zeropoint 40 [g] Variation of the weighbin. SiloHighCount Number of batches with the highness activated 100 before the controller initiates an alarm. SiloLowCount Number of batches with the lowsensor not activated 100 before the controller initiates an alarm. EmptyRegrind Indicates the ‘Empty Regrind’ regrind control No process is activated. EmptyRegrindHopper Indicates the hopper which is used in the empty Hopper 1 regrind process EmptyRegrindCycles Number of batches empty regrind waits before 1 increasing regrind (startprocess) Dispense inc/dec Maximum percentage for the regrind control 10 [%] processes

Dispense Number of steps in whitch the maximum must 10 VariationCycles be reached.

LoadcellGain Ampliﬁ cation-factor for the loadcell signal 16 LoadcellOverload Maximum weight in the weighbin. The controller 800 [g] initiates an error on this point. LoadcellSettleTime Time between the dispense of the last component 1 [s] and reading the weigbin-signal. (to eliminate vibrations). LoadcellWeight To read a correct weight 8 samples must ﬁ t to this 10 [g] BandWidth absolute band. FGB-Name/Nr. Name of the controller; This name is used in the user-interface of the terminal.

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3.6 Reports and overviews

There is the possibility of printing several reports and overviews. Underneath a list is made with the reports and overviews with behind them the section and page where instructions for printing are given.

* batch report § 3.5.1 * production report § 3.5.1 * material usage report § 3.3.2 * error report § 3.5.1 * recipe overview § 3.2.2 * component overview § 3.2.1 * alarm overview § 5.1

3.7 Settings of the user-interface

3.7.1 Change the rights of an operator

The terminal has some area’s which are protected by a password; protected-parameters, debug monitor etc. Before an operator can use, modify or see these area’s he has to perform a login procedure. This procedure starts by choosing menu (F1) ‘system / login’ the controllers asks now for an ID (see below). When the ID is correct the menu item login changes to logout.

To lock the system select menu (F1) ‘system / logout’ the menu item changes to login again.

3.7.2 Change entrycode

To change ID chose menu (F1) ‘system / change ID’.

IMPORTANT

Standard the ID is set to 1234. After it is changed the ID 1234 can’t be used.

There is no way to display the current ID so store the actual ID in a safe place.

When you lost the new code, please contact your dealer.

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3.7.3 Change date and time

Date and time of the terminal can be changed by entering menu (F1) ‘system / time and date’.

3.7.4 Revision code of the system

The terminal has the possibility to display the revision and those of the connected controllers. This information can be important for system-errors when you inform the dealer. To display this information chose menu (F1) ‘system / revision’

3.8 Menu hierarchy

PRODUCTION CONTROLLER RECIPES SYSTEM

Production status Select recipe Edit recipes Login/logout Change ID

Material usage Public parameters Edit components

Protected parameters Time and date Revision

Alarm history Cablibration >>>

Hardware reaction time

Digital I/O Loadcell monitor Loadcell tarration Select automatic mode Select manual mode

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Reference to section:

Production

Production status § 3.3.1 Material usage § 3.3.2

Controller

Select recipe § 2.1 Public parameters § 3.5.1 Protected parameters § 3.5.2 Alarm history § 5.1 Calibration Hardware reaction time § 3.4.3 Load cell § 3.4.1 Load cell tarration § 3.4.2 Digital I/O monitor § 3.3.3 Select automatic mode § 2.3 Select manual mode § 2.3

Recipes

Edit recipes § 3.2.2 Edit components § 3.2.1

System

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4.0 INSTALLATION

4.1 Services

For installation 1ph or 3ph supply is required dependent on type of unit and a 1/4” air supply with a minimum 6bar.

4.2 Mounting

There are several ways where to place the GraviMaster, namely

- on a frame

- on a mezzanine

- on the machine

Before mounting the unit ﬁ rst open the front panel and take out the mixing chamber. Make sure nothing is connected yet.

The front panel can be opened by opening the fasteners.

You can take out the mixer chamber and the weigh bin when the frontdoor is open.

4.2. Mountingplate

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The foot plate of the GraviMaster should be attached on a steel attachment plate on the frame or mezzanine or ﬂ ange pertinent to the machine.

The mounting holes are 9 mm and are positioned as shown in drawing 4.2

The unit should be mounted as stably as possible, in connection with the accuracy of the loadcell.

Now mixer chamber, the weighbin and the front panel can be replaced.

Connect the air pressure to the regulator (max. 12 bar). Put the plugs of the GraviMaster and the user interface in the sockets (220 V), these should be “clean”, without ﬂ uctuations and it must not be drawn off a 400 V wire. Then the communication cable should be plugged into the user-interface and the control-box.

The raw material supply should be connected to the hoppers. For startup refer to section 1 of chapter 2.

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5.0 Alarms

5.1 Alarm reports and solutions

The operating system sends a message to the terminal when a failure is detected. The message will be displayed and stored with date and time in the alarm history. Underneath is a list of all possible messages, with the solutions.

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ALARMS

Alarm-message Description Action to cancel alarm

Press enter Alarm already cancelled Press enter Operator must conﬁ rm

No control voltage No 24V control voltage present Turn on the main-switch or check fuses Covers open Security cover not present or mixerchamber Place security-cover / removed mixer-chamber

Production weight producedWeight equals produktionweight Reset the reached producedWeight No weighbin or Zero weight of the weighbin is greater then Loadcell must be calibrate ‘maximumTareVariation’ calibrated or a tare procedure must be done. Parameters corrupted The controller can’t read his parameters Check the parameters

correctly. All parameters will be ﬁ lled with standard values. Data corrupted The controller can’t read the productiondata Conﬁ rm

(production-screen). The data will be cleared. Hopper low The hoppersensor (optional) indicates that a Fill hopper with material hopper runs out of material. Hopper empty No material is dispensed so the controller

Fill hopper with material and

indicates that a hopper must be empty.

press the start-button.

***)

Loadcell not calibrated The controller can’t read the loadcell Calibrate the weighbin parameters correctly. Loadcell overload Weight of the weighbin is greater than the Remove material out of loadcellOverload parameter. the weigbin. Check in recipe the Loadcell not stable Weightsignal from the loadcell doesn’t ﬁ t Press enter

*) **)

the band.

Loadcell need Controller needs more samples to generate a Press enter

more samples stable weight. Loadcell boundary error

To much weight-samples doesn’t ﬁ t the band. Press enter

Silo high Silo supply hopper is full for several batches. Counter will (High sensor is activated) automaticaly cleared.

Regrind process par Given hoppernumbers doesn’t contain regrind Check the regrind conﬂ ict or percentage control parameters

Additive regrind par Given hoppernumber doesn’t contain additive Check the conﬂ ict AdditiveToRegind parameters

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*) If this error occurs frequently contact your dealer **) Other problems which initiate this error are:

- The weighbinDumpTime too short

- Weighbin valve touches the material when mixerchamber is full When the second problem occurs the position of the mixerchamber-sensor must be set

lower. This actions affects the total production capacity of your system.

***) Through a too short dispense valve opening time, the machine could think that there is

no material in the hopper. There are three possible reasons for this.

-1 dispense accuracy is too narrow

-2 dispense speed is too high

-3 number of dispense attempts is too low solutions:

-1 increase dispense accuracy (§ 3.5.2)

-2 adjust speed in recipe (§ 3.2.2)

-3 increase number of attempts (§ 3.5.2)

An error message on the terminal must be conﬁ rmed by pressing the <ENTER>-key. The

terminal stores all error messages these can be displayed by the menu (F1) ‘controller / alarm history’. This screen shows the last 256 errors and the number of times the error occurred. The error-list can de cleared by pressing (F2) option button and choose clear, with this button it is also possible to print a report of alarms, select ‘print alarm history’ and push <ENTER>.

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[0]OPERATING AUTO[ ] [ ] [ ]

STATUS:[0] FGB#00: (No name) STATUS OPERATING

----------------------------[ALARM HISTORY] No control voltage 1 Loadcell overload 0 Covers are open 1 Loadcell not stable 0 Production weight reached 0 Loadcell needs more samples 0 No Weighbin / Need calibration 0 Loadcell boundary error 0 Parameters are corrupted 0 Silo full error 0 Production data corrupted 0 Silo empty error 0 Hopper number (n) is empty 0 Conﬂ ict with regrind parameter 0 Loadcell is not calibrated 0 Conﬂ ict with addi.-regr.param 0

1 Date: 06-04-94 Time: 13:14:00 No control voltage 0 Date: 06-04-94 Time: 13:14:00 Covers are open

<Home>top of list <↑> scroll up <↓> scroll down

F1Menu F2Option F3 F4Clear F5Start F6Stop F7Pauze F8Cont.

If your problems can not be solved by these directives, please contact your dealer.

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6.0 MAINTENANCE AND REPAIR

Make sure ,when maintenance or repair is carried out, the power is shut off (by pulling the plugs out) and the air pressure (by disconnecting the air pressure).

6.1 Maintenance

Everything is set right and tested in the factory, adjustments should only be carried out if a part of the machine is not working correctly

Air pressure: Set air pressure to about 6 bar for best accuracy. However, lower

pressure will work. If your plant air ﬂ uctuates, set the regulator to the low end so that the dispense valves always see a consistent pressu re.

Level sensor: The sensor should protrude into the mixer chamber about 1 cm past

the inside surface of the stainless mounting plate. If it protrudes too far, it will sense the mixer blades. If it does not protrude far enough, it will sense the mounting plate itself.

Adjusting sensor sensitivity:

At the end of the sensor is a small screw, with this the sensitivity is adjustable.

step1: ﬁ ll the mixer chamber until the sensor is covered. step2: turn screw counter-clockwise until the led goes on (if the led already is on, then turn clockwise until led goes off and proceed with step 4). step3: turn screw clockwise until led goes off. step4: turn screw another 3/4 turn clockwise. step5: Empty the mixer chamber and check to be sure the sensor does not react on the mixer blades.

Weighbin dump valve:

The weighbin dump valve should open and close smoothly. Two airﬂ ow regula tors are attached on the cylinder. This can be adjusted by the screw that is on top of it.

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6.2 Replacement of parts

6.2.1 Replacement of printed circuit

For the replacement of the printed circuit of the control-box, the cover should be removed by unscrewing the bolts. unplug the connectors which are attached to the printed circuit. Now unscrew all M3 bolts and remove the circuit. It is important to ﬁ rst disconnect the connectors and then unscrew the bolts. attach the new printed circuit in the same way, but in reverse. It is wise to use a wrist band with ground cord which is connected with earth (PE). This because of the of static electricity.

6.3 Cleaning the machine

The frequency of cleaning will depend on the number of times the raw material is changed.

For cleaning the machine the front panel, the mixer chamber, the weighbin and the mixer should be removed (as described in section 4.2). Disconnect the electrical power and

air supply.

Clean the machine by using air pressure. Use safety-goggles when cleaning. After it has been cleaned, put it back together in the reverse way of stripping it.

6.4 Transportation of the GraviMaster

The weigh bin should be removed, before moving the GraviMaster, this can be done as described in the previous section. The weigh bin should be removed to prevent damaging the loadcell. The machine can now be transported on a ﬁ rm pallet.

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7.0 TECHNICAL INFORMATION

7.1 General machine speciﬁ cations

Connecting voltage : 1-phase 240 V Communication cable : Fiber optic cable (or RS–422) Air pressure : max. connecting pressure: 12 bar (+/- 170 psi) working pressure: 4-6 bar (+/- 57-86 psi) Sound level : < 70 dB (A) Surroundings temperature : -18°C to +50°C Batch weight : 0,5 kg Machine weight : 25 kg Machine dimensions : 450 x 450 x 640 mm

7.1.1 Safety measures

The GraviMaster is secured by 1 safety switch, which is positioned on the frontdoor. When the frontdoor is opened, the machine will stop.

7.2 User-interface speciﬁ cations

Connecting voltage : 240 V Printer connection : Parallel port

7.3 Valves speciﬁ cations

The machine is supplied with valves from the brand MAC, type 45A-SC1-DDAJ-1KJ. The number of valves is similar to the number of hoppers + 1 for the weighbin + 1 for the mixer chamber valve (optional).

The connection: (drawing 7 and 7.1) The valve of the weighbin is sealed at W1, so connection on W2 is the only possibility. Connecting dispenser valves H1 and H2 is as follows;

* H1-1 onto C1, as H2-1 onto C1 etc. * H1-2 onto C2, as H2-2 onto C2 etc.

H1-1 and H1-2 should be connected to the cylinder under hopper 1, H2-1 and H2-2 to the one under hopper 2 etc.

If there is a mixer chamber valve, it should be connected to B-1 and B-2, one of the lines is numbered, like one side of the cylinder. Connect the concordant ones.