MANUAL GraviMaster-FGB-M05 (S) Gravimetric Blender Serial No. ................... ISO 08.01.02.064.GB 986731 Rev.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 1.0 INTRODUCTION 2.0 CONTROLS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.7.1 2.7.2 2.7.2.1 2.7.2.2 2.7.3 2.7.4 2.7.5 2.7.5.1 2.7.5.2 2.7.6 2.7.7 2.8 2.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.8 Settings of the user-interface Change the rights of an operator Change entrycode Change date and time Revision code of the system Menu hierarchy 4.0 INSTALLATION 4.1 4.2 Demanded connections Attaching 5.0 ALARMS 5.1 Alarm reports and solutions 6.0 MAINTENANCE AND REPAIR 6.1 6.2 6.2.1 6.3 6.
Rev. May 2001 1.0 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 3 INTRODUCTION GRAVIMETRIC FEEDING An efficient materials blending system is an essential feature of the modern plastics processing industry. Dosing each component on the basis of weight shows distinct advantages over traditional volumetric systems. The quantity of material delivered is precise and unaffected by variations in bulk density, flow characteristics and particle size.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 4 RELIABLE PROCESS CONTROL The FGB control system incorporates the latest in computer and microprocessor technology for total automation of recipe entry and storage, inventory control and process monitoring. The control panel (user-interface) is provided with a micro-controller and industrial PC with LCD-display, functional keyboard, fiber optic communication cable (or RS-422) and parallel printer port.
Rev. May 2001 2.0 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 5 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 discharged into the mixing-chamber.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 6 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.
Rev. May 2001 2.4 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 7 Production-modes The production-mode of the blender indicates how the production will stop in automaticmode. 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.
Rev. May 2001 2.6 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 8 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 defined 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.
Rev. May 2001 2.7.2 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 9 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 defined in two ways: ‘Standard’ and ‘Percentage’. These methods can be defined in the recipe choosing menu (F1) ‘recipes / edit recipes’. The methods ‘Standard’ end ‘Percentage’ define the relation of the components (Regrind, Natural and Additive) in a recipe. 2.7.2.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 10 2.7.2.2 Method Percentage The different component are defined as follows: Regrind Natural Additive : : : Percentage of the batch weight Percentage of the batch weight Percentage of the batch weight Total sum must be 100%. Example Batchweight Regrind Natural 1 Natural 2 Additive Regrind Natural 1 Natural 2 Additive 2000 gr. 20.0% 60.0% 15.0% 5.0% : : : : 20.0% of 2000.0 60.0% of 2000.0 15.0% of 2000.0 5.0% of 2000.0 400.0 1200.0 300.
Rev. May 2001 2.7.4 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 11 Additive to regrind It is possible to dispense more additive in relation to the amount of regrind. Choose for this definition menu (F1) ‘controller / public parameters’. A maximum of two hoppers (additive) can be defined (additiveToRegrindHopper). The definition must be completed defining the requested percentage (additiveToRegrindPerc). ADDITIVE TO REGRIND Not activated 2.7.5 Activated with 2.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 12 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’.
Rev. May 2001 2.7.6 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 13 Dispensing Dispensing of the different components will start after the calculation of the related weights. The components are dispensed in the order as defined 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.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 14 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 first 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.
Rev. May 2001 2.8 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 15 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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Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 3.0 USER INTERFACE 3.1 Operator-interface 3.1.1 Keyboard Page 18 Description: F1 F2 F3 F4 Open main menu. All other sub-menu’s can be selected Open option menu. The contents is dependent of the actual screen. Will be used during calculation Choose node number The function keys F5 up to F8 is dependent of the machine mode (automatic, manual).
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 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 field can be changed by step) ENTER Select function. (choise is made and entered values are saved) .
Rev. May 2001 3.1.2 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 20 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 activates the selected object. Button After activating the button a command (or set of commands) is (are) executed.
Rev. May 2001 3.2.1 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 21 Change components There is a components list available in the controller. The list can be used by the operator to define 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 Natural Additive Scrap-material Basic-material Additive-material (e.g.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 22 In the screen it is possible to select a component with the arrow keys. After a component has been activated by the name and type can be changed. If the field type has been activated an option list will appear. One of the options (Regrind, Natural or Additive) must be chosen. By pressing the insert-button a new component will be added to the list. The controller places a standard name and type into the fields.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 23 If the character W has been found the ? key is pressed. Name ? Type [NATURAL] Step: Repeat the same procedure for the character H, I, T and E. When the whole name is given press . Now the name ‘WHITE” is stored. Name ?WHITE? Type [NATURAL] Step: Press the ? key again to select the type-field. Name [WHITE] Type NATURAL ? Step: Press to activate the field.
Rev. May 2001 3.2.2 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 24 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 -key deletes the current recipe of course there will be a conformation for the operator.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 25 FIELD OF A RECIPE Fields Description Number Unique recipe number Name Recipe name Colour Characterfield for the colour-name Batch Total batchweight Interpretation Recipe calculation Component Link hopper to component The screen can be left by pressing the -key. Now the terminal checks the recipe and if it is correct it will be stored.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 26 Actions: Step: Menu (F1) ‘recipes’ Step: ‘edit recipes’ Name Nr. Colour Step: Press the key (INS = insert) Number: Name: Colour: Batch: Interpretation: H# Component [1] ? [ [ 2.0] kg [ STANDARD ] 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.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 27 Step: Press the arrow-key <↓> once Interpretation: < STANDARD> Step: When the interpretation must be changed into PERCENTAGE press the key. Now select PERCENTAGE with the arrow keys and confirm with . Interpretation: STANDARD PERCENTAGE Step: Press the arrow key <↓> once. H# Component 1 2 : 12 QTY Alarm Speed (g/s) Step: Select the hopper you want to edit with the arrow-keys and press to activate.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 28 Step: Use the arrow-keys <↓> to select a component and press . Use the arrow-key to select Quantity. Enter the quantity and press . Use the arrow-key <→> to select Alarmtype and press . Alarm Ignore Ignore Warning Error Step: Select an alarm type by using the arrow-keys and press .
Rev. May 2001 3.3 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 29 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/outputscreen. 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.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 30 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# 1 2 3 4 5 6 7 8 9 10 11 12 Type REG NAT ADD totals [ACCEPT] F1Menu F8Cont. Recipe Requested [ 20.0] 400.0 [ 1.0] 1523.8 [ 5.0] 76.2 Dispensed Recipe 20.0 1.0 5.0 [UNDO CHANGES] 0.1 2000.
Rev. May 2001 3.3.3 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 31 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 is given the digital output will toggle. The operator has control of the digital outputs when the controller is in ‘manual mode’. 3.
Rev. May 2001 3.4.3 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 32 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.
Rev. May 2001 Parameter GraviMaster-FGB-M05 (S) Gravimetric Blender Page 33 PUBLIC PARAMETERS Description Init Interval Indicates if alarm-reports must be printed. No *) Indicates if production-reports must be printed. No *) If so the parameter interval-time must be given also. Pauze (time) before printing the next production-report. 01:00.00 BatchReport Indicates if batch-reports must be printed. No *) ProductionMode Actual production-mode.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 34 For example if the alarm report must be activated. First select the option field by using the up- and down-keys. Now press to activate the option field. If the option field 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 . Updating the parameters into the controller must be done for every parameter. 3.5.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 35 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 maximum accuracy 4 DispenseAccuracy Minimum accuracy for each component.
Rev. May 2001 3.6 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 36 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 * production report * material usage report * error report * recipe overview * component overview * alarm overview § 3.5.1 § 3.5.1 § 3.3.2 § 3.5.1 § 3.2.2 § 3.2.1 § 5.1 3.
Rev. May 2001 3.7.3 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 37 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.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Reference to section: Production Production status Material usage Controller Select recipe Public parameters Protected parameters Alarm history Calibration Hardware reaction time § Load cell Load cell tarration Digital I/O monitor Select automatic mode § Select manual mode Recipes Edit recipes Edit components System Login/logout Change ID Time and date Revision § § § § 3.4.3 § § § 2.3 § 3.3.1 § 3.3.2 2.1 3.5.1 3.5.2 § 5.1 3.4.1 3.4.2 3.3.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 4.0 INSTALLATION 4.1 Services Page 39 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 first open the front panel and take out the mixing chamber. Make sure nothing is connected yet.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 40 The foot plate of the GraviMaster should be attached on a steel attachment plate on the frame or mezzanine or flange 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).
Rev. May 2001 5.0 Alarms 5.1 Alarm reports and solutions GraviMaster-FGB-M05 (S) Gravimetric Blender Page 41 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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Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 43 *) **) 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.
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Rev. May 2001 6.0 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 45 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.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 6.2 Replacement of parts 6.2.1 Replacement of printed circuit Page 46 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 first disconnect the connectors and then unscrew the bolts. attach the new printed circuit in the same way, but in reverse.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender 7.0 TECHNICAL INFORMATION 7.1 General machine specifications 7.1.1 Connecting voltage Communication cable Air pressure : : : Sound level Surroundings temperature Batch weight Machine weight Machine dimensions : : : : : Page 47 1-phase 240 V Fiber optic cable (or RS–422) max.
Rev. May 2001 GraviMaster-FGB-M05 (S) Gravimetric Blender Page 48 Drawing 7.1 Cylinder Maschine 1 Ein 2 W H1 W= Wiegeschalenanschluss H1= Dosierschieber 1 H2= Dosierschieber 2 B= Mischkammerschieber (Option) Drawing 7.2 Topview valves 7.4 Air pressure cylinders specifications See specifications on cylinder.
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